High performance metal-supported solid oxide fuel cells fabricated by thermal spray

Suspension Plasma Spray and Performance Characterization of Half Cells with NiO/YSZ Anode and YSZ Electrolyte

“…In our previous study, SOFCs based on a Sm-doped ceria (SDC) electrolyte and NiO-SDC anode have been successfully fabricated by SPS (Ref 10,11). In this study, deposition of porous Ni-YSZ anodes and dense YSZ electrolytes on porous Hastelloy has been demonstrated by SPS using an axial injection plasma torch.…”

Break‐down of Losses in High Performing Metal‐Supported Solid Oxide Fuel Cells

“…These high temperatures tend to lead to serious corrosion of the metallic substrate. To solve the problem, different processing routes to fabricate electrodes and dense electrolytes on metallic supports have been employed, such as atmospheric plasma spray processing (APS) [3], vacuum plasma spraying (VPS) [4], suspension plasma spraying [5], high-velocity oxy-fuel (HVOF) spraying of liquid suspension feedstock [6], pulsed laser deposition (PLD) [7] and high temperature co-sintering in reducing atmosphere [1;8;9]. DTU Energy Conversion (part of former Risø DTU, hereafter referred to as DTU) has developed an unconventional cell design based on porous and highly electronically conducting layers into which electrocatalytically active anode materials (CGO and minor amounts of Ni) are infiltrated after sintering [10].…”

Metal supported tubular solid oxide fuel cells fabricated by suspension plasma spray and suspension high velocity oxy-fuel spray

“…2b shows a single cell with gas feeding components installed in a horizontal tube furnace for characterizing cell performance. [12]. In addition, the modeling data for Gd-doped ceria electrolyte based planar type metal supported single cells indicated that the power density of 200 mW cm -2 can be achieved at 570 C under 50% H 2 in Ar (3% H 2 O) [4].…”

“…1. The deposition of NiO-SDC and SDC on planar type metal supports by suspension thermal spray was already demonstrated at NRC [11,12], but the difference of support configuration, surface temperature distribution and control, and support cooling method for the deposition of anode and electrolyte on tubular type metal supports may cause difficulty in fabricating a highly dense and defect-free electrolyte layer on NiO-SDC anode deposited on a tubular metal support. In comparison to conventional thermal spray or HVOF spray, suspension plasma or HVOF spray has higher efficiency and deposition rate.…”