Solid oxide fuel cells (SOFCs) have the potential to meet the growing need for electrical power generation if the cost per megawatt can be further reduced. Currently, SOFC stacks are replaced too frequently to be cost competitive. SOFC service life can be extended by preventing chromium- (Cr-) bearing species from evaporating from the interior surfaces of balance of plant (BOP) components and poisoning the cathode to increase the lifetime. We have developed yttria-stabilized zirconia (YSZ) and aluminum oxide- (Al2O3-) modified sol-gel paints or inks for coating BOP components. 430 stainless steel (430SS) substrates with three surface conditions were coated with the 0.8–1.5 µm thick YSZ and Al2O3 paints. The coated 430SS samples were tested for thermal cycling resistance, thermal soak, and Cr evaporation. Thermal soak and thermal cycling test results show promise for the YSZ-coated 430SS substrates. The Cr evaporation test of a coated substrate showed a 51% reduction in Cr generation, when compared with a bare substrate.

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Dye-sensitized solar cells (DSSCs) based on mesoporous, high surface area nanocrystalline titania (TiO2) exhibiting up to 11% solar energy-conversion efficiencies are promising materials for cost-effective devices. Our objective here is to realize a cost-effective fabrication technique coupled with suitable device architecture of nanostructured DSSCs to achieve high photoconversion efficiencies. Atomic layer deposition (ALD) offers an attractive synthetic route for fabricating conformal photoanode coating materials on a nanoporous scaffold. Here, we used silica aerogels processed by doctor blading as structural scaffolds on transparent conducting oxide substrates, to promote subsequent conformal growth of thin films of TiO2 and aluminum-doped zinc oxide (AZO) by ALD. The resulting interdigitated architecture of the photoanodes can facilitate fast electron transfer. Dye sensitization of the photoanodes was accomplished using di-tetrabutylammonium cis-bis(isothiocyanato)bis(2,2'-bipyridyl-4,4'-dicarboxylate)ruthenium(II) ("N719", Dyesol, B2 dye) and assembled into photocells using liquid electrolytes. Co-sensitization with a second dye was found to increase the photon absorption and cell efficiency.

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