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A pulse and pulse reverse electrochemical deposition process is being developed for cost effective coating of solid oxide fuel cell (SOFC) interconnects. Faraday Technology and WVU demonstrated that the developed process could produce uniform dense, crack-free, well-adhered CoMn alloy coatings of various compositions on up to a 10 cm x 10 cm 441 stainless steel interconnect surface. The performance of various CoMn coatings has been evaluated before and after long duration thermal soak (~2000 hr @ 850°C) to determine the potential of each coating to mitigate Cr diffusion. The data included herein demonstrates the coatings potential while also identifying several challenges that need to be overcome before a successful coating can be scalably produce. Finally, we demonstrate the scalability of the FARADAYICSM Process via dual sided deposition of CoMn onto 10 cm x 10 cm T441 substrates.

A pulse reverse electrochemical surface finishing process for electropolishing passive materials is described. Unlike conventional electrochemical surface finishing processes, the pulse reverse process does not require low conductivity/high viscosity electrolytes and does not require the addition of chemical species to remove the passive film associated with electropolishing of passive and strongly passive materials. This paper focuses on pulse/pulse reverse electropolishing of niobium and Nitinol.

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A pulse electrodeposition process is being developed and validated for coating ferritic stainless steel solid oxide fuel cell interconnects with a cobalt-manganese alloy. The electrodeposition process produces the alloy coatings from a single acidic sulfate based electrolyte containing cobalt and manganese ions, sodium gluconate, ammonium sulfate and boric acid. Subsequent to electrodeposition, the alloy coatings are oxidized at elevated temperatures to form spinel structures. Experiments demonstrate that the pulse waveform parameters influence the chemical composition of the alloy coating. Survival of long term exposure at elevated temperatures has shown that the coatings function as a barrier to chrome diffusion toward the surface with minimal increase in the area specific resistance.