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Red-flap grid Blue-back ground cut out box Blue-rigid Red-elastic

The current paper reports the details of challenges and progress in the joint project on development of metal supported solid oxide fuel cells and stacks by the teams of German Aerospace Center (DLR), ElringKlinger, Sulzer Metco and Plansee. An account of the materials is given followed by the advances in the processing techniques which include alternative plasma spraying and colloidal spraying. Improvement in the cell and stack design is then discussed followed by challenges faced during stack building and operations and solution implemented.

PEM electrolysis is a promising technology for large scale storage of surplus electricity, though it is still costly mainly due to the manufacture of large area and high purity Ti bipolar plates (BPP). In this work we have developed an Au/Ti coating deposited by electrodeposition/thermal spraying on stainless steel BPP. The coating was physically characterized with SEM and electrochemically evaluated in simulated anode conditions. Interfacial contact resistance (ICR) vs. compaction pressure measurements showed that the coating is highly conductive. It successfully protected the stainless steel substrate from corrosion. However, the Au modification detached after 6 h of application of a potential of 2 V vs. RHE. Consequently the Au modification has to be replaced by either another precious metal or a corrosion resistant electroceramic. The coating reported herein could have a large impact on the cost of PEM electrolyzers for large scale electricity storage from renewables.