A modeling framework for the numerical reconstruction of the microstructure of infiltrated electrodes is presented in this study. A particle-based sedimentation algorithm is used to generate the backbone, while a novel packing algorithm is used to randomly infiltrate nanoparticles on the surface of backbone particles. The effective properties, such as the connected triple-phase boundary length, the effective conductivity, the effective diffusivity, are evaluated on the reconstructed electrodes by using geometric analysis, finite volume and random-walk methods, and reported in dimensionless form to provide generality to the results. A parametric study on the effect of the main model and operating parameters is performed. Simulations show that the critical loading (i.e., the percolation threshold) increases as the backbone porosity decreases and the nanoparticle diameter increases. Large triple-phase boundary length, specific surface area and good effective conductivity can be reached by infiltration, without detrimental effects on the effective transport properties in gas phase. Simulations reveal a significant sensitivity to the size and contact angle of infiltrated particles, suggesting that the preparation process of infiltrated electrodes should be properly tailored in order to obtain the optimized structures predicted by the model. In the last decade, much attention has been drawn toward nanostructured electrodes for solid oxide fuel cells (SOFCs) prepared via infiltration techniques.1-7 The main reason is reduced polarization resistance, with corresponding increased power density, in comparison with conventional electrodes prepared via traditional mixing and sintering processes. The improved performance of infiltrated electrodes holds even at intermediate temperatures (500-800• C), as demonstrated by a large number of experimental studies. [8][9][10][11][12][13] Other technological advantages are a wide choice of catalyst materials, a good adhesion and a reduced thermal expansion mismatch between the electrode and the electrolyte.3 On the other hand, the long-term stability and the fabrication cost of nanostructured electrodes still need to be properly addressed.
2,3The infiltration (or impregnation) technique involves the deposition of nanoparticles into a pre-sintered backbone of micrometer-size particles.1,3 The backbone is a skeletal structure typically composed of a single component, such as yttria-stabilized zirconia (YSZ) 5,8 or, in alternative, a mixed ionic-electronic conductor (e.g., lanthanum strontium cobalt ferrite LSCF).14 However, composite backbones, such as the usual lanthanum strontium manganite (LSM)/YSZ cathode, have also been used. 1,15 The sintering of the backbone is performed at high temperature in order to ensure structural stability of the electrode and good connection among backbone particles. 3 In the following step, nanoparticles are infiltrated in the backbone using different methods (such as metal salt precipitation, 2 nanoparticle dispersion, 16 molten salts) 1 and then sinte...