Industrial-scale high power impulse magnetron sputtering of yttria-stabilized zirconia on porous NiO/YSZ fuel cell anodes

Sønderby, Søren Kaae; Christensen, B.H.; Almtoft, Klaus Pagh; Nielsen, Lars Peter; Eklund, Per

doi:10.1016/j.surfcoat.2015.09.058

Cited by 29 publications

(18 citation statements)

References 46 publications

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“…Great efforts have been made to apply reactive magnetron sputtering to build gastight, thin electrolytes on the anode support . Fabrication of gastight thin film electrolytes on porous anode supports is not an easy task because the surface of the anode support usually contains pores with diameters in the range of several micrometers, which leads to pinholes formation.…”

Section: Introductionmentioning

confidence: 99%

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Scale‐up of Solid Oxide Fuel Cells with Magnetron Sputtered Electrolyte

et al. 2017

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The possibility of fabricating large‐area solid oxide fuel cells (SOFC) with thin film electrolyte using a commercial physical vapor deposition technology is investigated. Yttria‐stabilized zirconia (YSZ)/gadolinium‐doped ceria (GDC) bilayer electrolyte is successfully deposited on a 10 × 5 cm2 commercial NiO/YSZ anode support by reactive magnetron sputtering. The microstructure of the fuel cells was studied by scanning electron microscopy. Current‐voltage characteristics of fuel cells at a temperature of 750°C and their power stability under electrical load were investigated. Single cells with La0.6Sr0.4Co0.2Fe0.8O3/ Gd0.1Ce0.9O1.95 (LSCF/GDC) cathode had an open cell voltage of 1.14 V and a maximum power density of 490 mW cm−2 at 750 °C using H2/N2 gas mixture as fuel and air as the oxidant. Three‐cell planar SOFC stack using 10 × 5 cm2 anode‐supported unit cells with power density of 450 mW cm−2 at a voltage of 0.7 V per cell has been assembled and tested.

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Section: Introductionmentioning

confidence: 99%

“…This cell's size is obviously insufficient for the manufacture and testing of SOFS stacks. Sønderby et al demonstrated deposition of YSZ thin films by high power impulse magnetron sputtering in an industrial setup on 13 × 13 cm 2 porous NiO/YSZ fuel cell anodes. However, a whole fuel cell in this work was not produced and investigated.…”

Section: Introductionmentioning

confidence: 99%

Scale‐up of Solid Oxide Fuel Cells with Magnetron Sputtered Electrolyte

et al. 2017

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“…Most often to deposit YSZ electrolyte, sputtering in DC-pulsed mode is used. However, in the works of Sonderby et al [37,38], for depositing the YSZ electrolyte on NiO/YSZ anodes, high power impulse magnetron sputtering was used. HiPIMS utilizes extremely high power densities of the order of kW/cm 2 in short pulses of tens of microseconds at low duty cycle (on/off time ratio) of <10%.…”

Section: Magnetron Sputtering Of Ysz Electrolyte Effect Of Depositiomentioning

confidence: 99%

“…In their next paper, Sonderby and co-authors [38] optimized the parameters of high power reactive magnetron sputtering and the magnitude of the bias voltage. As a result, YSZ electrolytes up to 3 µm thick are deposited on the anodes with an area of (13 × 13) cm 2 .…”

Section: Magnetron Sputtering Of Ysz Electrolyte Effect Of Depositiomentioning

confidence: 99%

Magnetron deposition of yttria-stabilised zirconia electrolyte for solid oxide fuel cells

Solovyev

Шипилова

Работкин

et al. 2018

Eurasian j. phys. funct. mater.

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The aim of the article is to review the latest achievements in the field of magnetron deposition of thinfilm yttria-stabilised zirconia (YSZ) electrolyte for solid oxide fuel cells (SOFC). The main attention is paid to the use of magnetron sputtering for formation of YSZ electrolyte up to 10 µm thick on the anode substrates of intermediate-temperature SOFCs operating at a temperature of (600 − 800) • C . The influence of the types of power sources and such deposition parameters as substrate temperature, substrate bias voltage, post-annealing treatment, etc., as well as the morphology of the anode substrate surface on the microstructure and properties of the deposited electrolyte is analyzed. It is shown that the magnetron sputtering method, despite its relatively high cost and complexity, is applicable to large area SOFC cells and is competitive compared to traditional methods of electrolyte formation, such as tape casting, tape calendering, electrophoretic deposition and screen printing.

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“…The tetragonal phase is the most commonly used phase and can be stabilized at STP by alloying with different early transition metal oxides, the most common being Y2O3 [58,59]. The cubic fluoride phase is used as electrolyte in solid-oxide fuel cells due to its high ionic conductance [60,61].…”

Section: Zro2 Polymorphsmentioning

confidence: 99%

Thin Film and Plasma Characterization of PVD Oxides

Landälv¹

2017

Linköping Studies in Science and Technology. Dissertations

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The state-of-the-art tools for machining metals are primarily based on a metal-ceramic composite (WC-Co) coated with different combinations of carbide, nitride and oxide coatings. Combinations of these coating materials are optimized to withstand specific wear conditions. Oxide coatings are especially desired because of their possible high hot hardness, chemical inertness with respect to the workpiece, and their low friction.This thesis deals with process and coating characterization of new oxide coatings deposited by physical vapor deposition (PVD) techniques, focusing on the Cr-Zr-O and Al-Cr-Si-O systems.The thermal stability of α-Cr0.28Zr0.10O0.61 deposited by reactive radio frequency (RF)-magnetron sputtering at 500 °C was investigated after annealing up to 870 °C. The annealed samples showed transformation of α-(Cr,Zr)2O3 and amorphous ZrOx-rich areas into tetragonal ZrO2 and bcc Cr. The instability of the α-(Cr,Zr)2O3 is surprising and possibly related to the annealing being done under vacuum, facilitating the loss of oxygen. The stabilization of the room temperature metastable tetragonal ZrO2 phase, due to surface energy effects, may prove to be useful for metal cutting applications. The observed phase segregation of α-(Cr,Zr)2O3 and formation of tetragonal ZrO2 with corresponding increase in hardness for this pseudo-binary oxide system also opens up design routes for pseudo-binary oxides with tunable microstructural and mechanical properties.The inherent difficulties of depositing insulating oxide films with PVD, demanding a closed circuit, makes the investigation of process stability an important part of this research. In this context, we investigated the influence of adding small amount of Si in Al-Cr cathode on plasma characteristics, process parameters, and coating properties. Si was chosen here due to a previous study showing improved erosion behavior of Al-Cr-Si over pure Al-Cr cathode without Si incorporation in the coating.This work shows small improvements in cathode erosion and process stability (lower pressure and cathode voltage) when introducing 5 at % Si in the Al70Cr30-cathode. This also led to fewer droplets at low cathode current and intermediate O2 flow. A larger positive effect on cathode erosion was observed with respect to cleaning the cathode from oxide contamination by increasing cathode current with 50%. However, higher cathode current also resulted in increased amount of droplets in the coating which is undesirable. Through plasma analysis the presence of volatile SiO species could be confirmed but the loss of Si through volatile SiO species was negligible, since the coating composition matched the cathode composition. The positive effect of added Si on the process stability at the cathode surface should be weighed against Si incorporation in the coating. This incorporation may or may not be beneficial for the final application since literature states that Si promotes the metastable γ-phase over the thermodynamically stable α-phase of pure Al2O3, contrary to the effect o...

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Industrial-scale high power impulse magnetron sputtering of yttria-stabilized zirconia on porous NiO/YSZ fuel cell anodes

Cited by 29 publications

References 46 publications

Scale‐up of Solid Oxide Fuel Cells with Magnetron Sputtered Electrolyte

Scale‐up of Solid Oxide Fuel Cells with Magnetron Sputtered Electrolyte

Magnetron deposition of yttria-stabilised zirconia electrolyte for solid oxide fuel cells

Thin Film and Plasma Characterization of PVD Oxides

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