Search Results (39)

This paper investigates the application of non-calcined metal tartrate as a novel alternative pore former to prepare functional ceramic composites to fabricate solid oxide fuel cells (SOFCs). Compared to carbonaceous pore formers, non-calcined pore formers offer high compatibility with various ceramic composites, providing better control over porosity and pore size distribution, which allows for enhanced gas diffusion, reactant transport and gaseous product release within the fuel cells’ functional layers. In this work, nanocrystalline gadolinium-doped ceria (GDC) and Ni-Gd-Ce-tartrate anode powders were prepared using a single-step co-precipitation synthesis method, based on the carboxylate route, utilising ammonium tartrate as a low-cost, environmentally friendly precipitant. The non-calcined Ni-Gd-Ce-tartrate was used to fabricate dense GDC electrolyte pellets (5–20 μm thick) integrated with a thin film of Ni-GDC anode with controlled porosity at 1300 °C. The dilatometry analysis showed the shrinkage anisotropy factor for the anode substrates prepared using 20 wt. The percentages of Ni-Gd-Ce-tartrate were 30 wt.% and 40 wt.%, with values of 0.98 and 1.01, respectively, showing a significant improvement in microstructural properties and pore size compared to those fabricated using a carbonaceous pore former. The results showed that the non-calcined pore formers can also lower the sintering temperature for GDC to below 1300 °C, saving energy and reducing thermal stresses on the materials. They can also help maintain optimal material properties during sintering, minimising the risk of unwanted chemical reactions or contamination. This flexibility enables the versatile designing and manufacturing of ceramic fuel cells with tailored compositions at a lower cost for large-scale applications. Full article

Epitaxial layers of water-soluble Sr₃Al₂O₆ were fabricated as sacrificial layers on SrTiO₃ (100) single-crystal substrates using the Pulsed Laser Deposition technique. This approach envisages the possibility of developing a new generation of micro-Solid Oxide Fuel Cells and micro-Solid Oxide Electrochemical Cells for portable energy conversion and storage devices. The sacrificial layer technique offers a pathway to engineering free-standing membranes of electrolytes, cathodes, and anodes with total thicknesses on the order of a few nanometers. Furthermore, the ability to etch the SAO sacrificial layer and transfer ultra-thin oxide films from single-crystal substrates to silicon-based circuits opens possibilities for creating a novel class of mixed electronic and ionic devices with unexplored potential. In this work, we report the growth mechanism and structural characterization of the SAO sacrificial layer. Epitaxial samarium-doped ceria films, grown on SrTiO3 substrates using Sr₃Al₂O₆ as a buffer layer, were successfully transferred onto silicon wafers. This demonstration highlights the potential of the sacrificial layer method for integrating high-quality oxide thin films into advanced device architectures, bridging the gap between oxide materials and silicon-based technologies. Full article

Solid oxide fuel cells (SOFCs) are attracting attention as an eco-friendly power source because they show high power density. However, SOFC requires a high-temperature environment of 800 °C or higher, and accordingly, the problem of thermal stability of the material constituting SOFC has been raised. On the other hand, low-temperature solid oxide fuel cells (LT-SOFCs) research is steadily progressing to improve the electrochemical performance at low temperatures by improving the oxygen reduction reaction of the cathode by applying a cathode interlayer of various materials. In this study, LT-SOFCs were manufactured and electrochemically evaluated using praseodymium oxide (PrO_x) as a cathode interlayer. Scandium Stabilized Zirconia (ScSZ) pellets were used as electrolyte support for LT-SOFC, and PrO_x was deposited by various thicknesses as a cathode interlayer on ScSZ pellets by a sputtering process. Pt and Ni were deposited under the same process conditions for the cathode and anode, respectively. To analyze the thin-film characteristics of the PrO_x cathode interlayer, SEM (Scanning Electron Microscopy), X-ray Diffraction (XRD), and XPS (X-ray Photoelectron Spectroscopy) were analyzed. The electrochemical characteristics of LT-SOFCs were evaluated by electrochemical impedance spectroscopy (EIS). Hydrogen was supplied to the anode at the flow rate of 50 sccm, and the performance of LT-SOFC was evaluated at 500 °C by exposing the cathode to the atmosphere. Full article

Thin films of gadolinium-doped ceria (GDC) nanoparticles were fabricated as electrolytes for low-temperature solid oxide fuel cells (SOFCs) by combining electrophoretic deposition (EPD) and the successive ionic layer adsorption and reaction-air spray plus (SILAR-A+) method. The Ce_1−xGd_xO_2−x/2 solid solution was synthesized using hydrothermal (HY) and solid-state (SS) procedures to produce high-quality GDC nanoparticles suitable for EPD fabrication. The crystalline structure, cell parameters, and phases of the GDC products were analyzed using X-ray diffraction. Variations in oxygen vacancy concentrations in the GDC samples were achieved through the two synthetic methods. The ionic conductivities of pressed pellets from the HY, SS, and commercial G_0.2DC samples, measured at 150 °C, were 0.6 × 10⁻⁶, 2.6 × 10⁻⁶, and 2.9 × 10⁻⁶ S/cm, respectively. These values were determined using electrochemical impedance spectroscopy (EIS) with a simplified equivalent circuit method. The morphologies of G_0.2DC thin films prepared via EPD and SILAR-A+ processes were characterized, with particular attention to surface cracking. Crack-free GDC thin films, approximately 730–1200 nm thick, were successfully fabricated on conductive substrates through the hybridization of EPD and SILAR-A+, followed by hydrothermal annealing. EIS and ionic conductivity (1.39 × 10⁻⁹ S/cm) measurements of the G_0.2DC thin films with thicknesses of 733 nm were performed at 300 °C. Full article

In this study, a detailed structural characterization of epitaxial ${\text{La}}_{0.6}$${\text{Sr}}_{0.4}$${\text{CoO}}_{3-\delta }$ (LSC) films grown in (100), (110), and (111) orientations was conducted. LSC is a model air electrode material in solid oxide fuel and electrolysis cells and understanding the correlation of bulk structure and catalytic activity is essential for the design of future electrode materials. Thin films were grown on single crystals of the perovskite material ${\text{La}}_{0.95}$${\text{Sr}}_{0.05}$${\text{Ga}}_{0.95}$${\text{Mg}}_{0.05}$${\text{O}}_{3-\delta }$ cut in three different directions. This enabled an examination of structural details at the atomic scale for a realistic material combination in solid oxide cells. The investigation involved the application of atomic force microscopy, X-ray diffraction, and high-resolution transmission electron microscopy to explore the distinct properties of these thin films. Interestingly, ordering phenomena in both cationic as well as anionic sublattices were found, despite the fact that the thin films were never at higher temperatures than 600 °C. Cationic ordering was found in spherical precipitates, whereas the ordering of oxygen vacancies led to the partial transition to brownmillerite in all three orientations. Our results indicate a very high oxygen vacancy concentration in all three thin films. Lattice strains in-plane and out-of-plane was measured, and its implications for the structural modifications are discussed. Full article

A NiO-10YSZ/10YSZ half-cell for anode-supported solid oxide fuel cells (SOFCs) was fabricated using 3D inkjet printing and layer-by-layer laser treatment of printing compositions followed by thermal sintering by a co-firing method. The optimal granulometric composition and rheological characteristics of the printing compositions to fabricate the NiO-10YSZ (60:40 wt.%) anode support, NiO-10YSZ (40:60 wt.%) anode functional layer (AFL), and 10YSZ electrolyte were determined. Effects of the pore former and laser post-treatment on the morphology of the as-prepared anodes for the manufacture of SOFC anode supports were studied, and the optimum laser exposure for hybrid 3D printing was determined. A mechanism of influence of the exposure of laser post-treatment on the morphology of the NiO-10YSZ anode supports has been proposed. The mass content of 10YSZ and the number of layers were shown to affect the surface microstructure and the thickness of the thin-film electrolytes deposited on the surface of the anode supports. The hybrid inkjet 3D printing offers great opportunities as it allows a one-pot procedure to fabricate a NiO-10YSZ/10YSZ SOFC half-cell for SOFC anode supports. Full article

Solid oxide fuel cells (SOFCs) are amongst the most widely used renewable alternative energy systems with near-zero carbon emission, high efficiency, and environment-friendly features. However, the high operating temperature of SOFCs is still considered a major challenge due to several issues regarding the materials’ corrosion, unwanted reactions between layers, etc. Thus, low-temperature SOFCs (LT-SOFCs) have gained significant interest during the past decades. Despite the numerous advantages of LT-SOFCs, material selection for each layer is of great importance as the common materials have not shown a desirable performance so far. In addition to the selection of the materials, fabrication techniques have a great influence on the properties of the SOFCs. As SOFCs with thinner layers showed lower polarisation resistance, especially in the electrolyte layer, different thin-film fabrication methods have been employed, and their effect on the overall performance of SOFCs has been evaluated. In this review, we aim to discuss the past and recent progress on the materials and thin-film fabrication techniques used in LT-SOFCs. Full article

In this study, the formation of thin-film barrier coatings based on a highly conductive Bi_1.60Er_0.4O₃ (EDB) solid electrolyte on supporting Ce_0.8Sm_0.2O_1.9 (SDC) electrolyte substrates was implemented for the first time using electrophoretic deposition (EPD). The electrokinetic properties of EDB-based suspensions in a non-aqueous dispersion medium of isopropanol modified with small additions of polyethyleneimine (PEI, 0.26 g/L) and acetylacetone (0.15 g/L), as well as in a mixed isopropanol/acetylacetone (70/30 vol.%) medium, were studied. The dependences of the thickness of the EDB coatings on voltage and deposition time were obtained using deposition on a model Ni foil electrode. Preliminary synthesis of a conductive polypyrrole (PPy) polymer film was used to create surface conductivity on non-conductive SDC substrates. The efficiency of using a modified dispersion medium based on isopropanol to obtain a continuous EDB coating 12 μm thick, sintered at a temperature of 850 °C for 5 h, is shown. The microstructure and morphology of the surface of the EDB coating were studied. A Pt/SDC/EDB/Pt cell was used to characterize the coating’s conductivity. The EPD method is shown to be promising for the formation of barrier coatings based on doped bismuth oxide. The developed method can be used for creating cathode barrier layers in SOFC technology. Full article

Samarium-doped ceria (SDC) is considered as an alternative electrolyte material for intermediate-temperature solid oxide fuel cells (IT-SOFCs) because its conductivity is higher than that of commonly used yttria-stabilized zirconia (YSZ). The paper compares the properties of anode-supported SOFCs with magnetron sputtered single-layer SDC and multilayer SDC/YSZ/SDC thin-film electrolyte, with the YSZ blocking layer 0.5, 1, and 1.5 μm thick. The thickness of the upper and lower SDC layers of the multilayer electrolyte are constant and amount to 3 and 1 μm, respectively. The thickness of single-layer SDC electrolyte is 5.5 μm. The SOFC performance is studied by measuring current–voltage characteristics and impedance spectra in the range of 500–800 °C. X-ray diffraction and scanning electron microscopy are used to investigate the structure of the deposited electrolyte and other fuel cell layers. SOFCs with the single-layer SDC electrolyte show the best performance at 650 °C. At this temperature, open circuit voltage and maximum power density are 0.8 V and 651 mW/cm², respectively. The formation of the SDC electrolyte with the YSZ blocking layer improves the open circuit voltage up to 1.1 V and increases the maximum power density at the temperatures over 600 °C. It is shown that the optimal thickness of the YSZ blocking layer is 1 µm. The fuel cell with the multilayer SDC/YSZ/SDC electrolyte, with the layer thicknesses of 3/1/1 µm, has the maximum power density of 2263 and 1132 mW/cm² at 800 and 650 °C, respectively. Full article

The strategy to increase the performance of the single solid oxide fuel cell (SOFC) with a supporting membrane of Ce_0.8Sm_0.2O_1.9 (SDC) electrolyte has been implemented in this study by introducing a thin anode barrier layer of the BaCe_0.8Sm_0.2O₃ + 1 wt% CuO (BCS-CuO) electrolyte and, additionally, a modifying layer of a Ce_0.8Sm_0.1Pr_0.1O_1.9 (PSDC) electrolyte. The method of electrophoretic deposition (EPD) is used to form thin electrolyte layers on a dense supporting membrane. The electrical conductivity of the SDC substrate surface is achieved by the synthesis of a conductive polypyrrole sublayer. The kinetic parameters of the EPD process from the PSDC suspension are studied. The volt-ampere characteristics and power output of the obtained SOFC cells with the PSDC modifying layer on the cathode side and the BCS-CuO blocking layer on the anode side (BCS-CuO/SDC/PSDC) and with a BCS-CuO blocking layer on the anode side (BCS-CuO/SDC) and oxide electrodes have been studied. The effect of increasing the power output of the cell with the BCS-CuO/SDC/PSDC electrolyte membrane due to a decrease in the ohmic and polarization resistances of the cell is demonstrated. The approaches developed in this work can be applied to the development of SOFCs with both supporting and thin-film MIEC electrolyte membranes. Full article

Solid oxide cells are capable of efficiently converting various chemical energy carriers to electricity and vice versa. The urgent challenge nowadays is the faster degradation rate compared with other fuel cell/electrolyzer technologies. To understand the degradation mechanisms, simulation of a solid oxide cell is helpful. Since most previous research developed models using commercial software, such as COMSOL and ANSYS Fluent, a gap for knowledge transfer is being gradually formed between academia and industry due to licensing issues. This paper introduces a multiphysics model, developed by a computational code, openFuelCell2. The code is implemented with an open-source library, OpenFOAM. It accounts for momentum transfer, mass transfer, electrochemical reactions and metal interconnect oxidation. The model can precisely predict I–V curves under different temperatures, fuel humidity and operation modes. Comparison between OpenFOAM and COMSOL simulations shows good agreement. The metal interconnect oxidation is modeled, which can predict the thickness of the oxide scale under different protective coatings. Simulations are conducted by assuming an ultra-thin film resistance on the rib surface. It is revealed that coatings fabricated by atmospheric plasma spraying can efficiently prevent metal interconnect oxidation, with a contribution of only 0.53 % to the total degradation rate. Full article

Fuel electrode-supported tubular protonic ceramic cells (FETPCCs) based on the BaZr_0.4Ce_0.4Y_0.15Zn_0.05O_3−δ (BZCYZ) membrane electrolyte was fabricated through a two-step method, in which the polyporous electrode-support tube was prepared with a traditional slip casting technique in a plaster mold, and the BZCYZ membrane was produced by a dip-coating process on the outside surface of the electrode-support tube. The dense thin-film electrolyte of BZCYZ with a thickness of ~25 μm was achieved by cofiring the fuel electrode support and electrolyte membrane at 1450 °C for 6 h. The electrochemical performances of the FETPCCs were tested under different solid oxide cell modes. In protonic ceramic fuel cell (PCFC) mode, the peak power densities of the cell reached 151–191 mW·cm⁻² at 550–700 °C and exhibited relatively stable performance during continuous operation over 100 h at 650 °C. It was found that the major influence on the performance of tubular PCFC was the resistance and cathode current collectors. Additionally, in protonic ceramic electrolysis cell (PCEC) mode, the current densities of 418–654 mA·cm⁻² were obtained at 600–700 °C with the applied voltage of 2.0 V when exposed to 20% CO₂–80% H₂ and 3% H₂O/air. Using distribution of relaxation time analysis, the electrolytic rate-limiting step of the PCEC model was determined as the adsorption and dissociation of the gas on the electrode surface. Full article

A perovskite La_1−xSr_xMnO₃ cathode thin film for an oxygen ion conducting solid oxide fuel cell was prepared using a low power (8.8 kW) liquid solution plasma spray method. Usually, a 30–50 kW Ar plasma torch with temperature higher than all the melting points of solid precursors is essential to synthesis oxides thin film. However, using the liquid precursors as the feeding materials, the required power can be reduced and save a lot of thermal budget. The precursors are water solutions of lanthanum nitrate hexahydrate, manganese(II) nitrate tetrahydrate, and strontium nitrate. The atomic percentage of La in the plasma sprayed La_1−xSr_xMnO₃ cathode film is lower than that of La in the feeding precursor into the torch, which is due to the low boiling temperature of La(NO₃)₃ precursor. The oxygen stoichiometry of La_1−xSr_xMnO_3−δ deduced from the valence state of Mn measured by X-ray absorption spectroscopy shows an oxygen deficit structure. The measured low resistivity of 0.07–0.09 Ωcm at room temperature for this La_1−xSr_xMnO_3−δ is essential for oxygen ion transport in the cathode thin film of a solid-state fuel cell. Full article

To obtain highly homogeneous cobalt–nickel aluminate spinels with small crystallite sizes, CoNiAl alloy thin films were primarily deposited using Laser-induced Thermionic Vacuum Arc (LTVA) as a versatile method for performing processing of multiple materials, such as alloy/composite thin films, at a nanometric scale. Following thermal annealing in air, the CoNiAl metallic thin films were transformed into ceramic oxidic (Co,Ni)Al₂O₄ with controlled composition and crystallinity suitable for thermal stability and chemical resistance devices. Structural analysis revealed the formation of (Co,Ni)Al₂O₄ from the amorphous CoNiAl alloys. The mean crystallite size of the spinels was around 15 nm. Thermal annealing induces a densification process, increasing the film thickness together with the migration process of the aluminum toward the surface of the samples. The sheet resistance changed drastically from 200–240 Ω/sq to more than 10⁶ Ω/sq, revealing a step-by-step conversion of the metallic character of the thin film to a dielectric oxidic structure. These cermet materials can be used as inert anodes for the solid oxide fuel cells (SOFCs), which require not only high stability with respect to oxidizing gases such as oxygen, but also good electrical conductivity. These combination metal–ceramics are known as bi-layer anodes. By controlling the crystallite size and the interplay between the oxide/metal composite, a balance between stability and electrical conductivity can be achieved. Full article

Mixed ionic-electronic conducting materials are not used as a single-layer electrolyte of solid oxide fuel cells (SOFCs) at relatively high operating temperatures of ~800 °C. This is because of a significant decrease in the open-circuit voltage (OCV) and, consequently, the SOFC power density. The paper presents a comparative analysis of the anode-supported SOFC properties obtained within the temperature range of 600 to 800 °C with yttria-stabilized zirconia (YSZ) electrolyte and gadolinium-doped ceria (GDC) electrolyte thin films. Electrolyte layers that are 3 µm thick are obtained by magnetron sputtering. It is shown that at 800 °C, the SOFC with the GDC electrolyte thin film provides an OCV over 0.9 V and power density of 2 W/cm². The latter is comparable to the power density of SOFCs with the YSZ electrolyte, which is a purely ionic conductor. The GDC electrolyte manifests the high performance, despite the SOFC power density loss induced by electronic conductivity of the former, which, in turn, is compensated by its other positive properties. Full article