Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell
A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an electrode structure of an electrochemical cell by: (A) providing an electrode structure; (B) forming on a selected portion of the electrode surface, an interconnection layer having the general formula La{sub 1{minus}x}M{sub x}Cr{sub 1{minus}y}N{sub y}O{sub 3}, where M is a dopant selected from the group of Ca, Sr, Ba, and mixtures thereof, and where N is a dopant selected from the group of Mg, Co, Ni, Al, and mixtures thereof, and where x and y are each independently about 0.075--0.25, by thermally spraying, preferably plasma arc spraying, a flux added interconnection spray powder, preferably agglomerated, the flux added powder comprising flux particles, preferably including dopant, preferably (CaO){sub 12}(Al{sub 2}O{sub 3}){sub 7} flux particles including Ca and Al dopant, and LaCrO{sub 3} interconnection particles, preferably undoped LaCrO{sub 3}, to form a dense and substantially gas-tight interconnection material bonded to the electrode structure by a single plasma spraying step; and (C) heat treating the interconnection layer at from about 1,200 to 1,350 C to further densify and heal the micro-cracks and macro-cracks of the thermally sprayed interconnection layer. The result is a substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode structure. The electrode structure can be an air electrode, and a solid electrolyte layer can be applied to the unselected portion of the air electrode, and further a fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell for generation of electrical power. 4 figs.
- Research Organization:
- Westinghouse Electric Corporation
- DOE Contract Number:
- FC21-91MC28055
- Assignee:
- Westinghouse Electric Corp., Pittsburgh, PA (United States)
- Patent Number(s):
- US 5,391,440/A/
- Application Number:
- PAN: 8-195,335
- OSTI ID:
- 27707
- Resource Relation:
- Other Information: PBD: 21 Feb 1995
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
SOLID ELECTROLYTE FUEL CELLS
ELECTRODES
FABRICATION
COATINGS
PLASMA ARC SPRAYING
LANTHANUM OXIDES
CHROMIUM OXIDES
DOPED MATERIALS
CALCIUM OXIDES
STRONTIUM OXIDES
BARIUM OXIDES
MAGNESIUM OXIDES
COBALT OXIDES
NICKEL OXIDES
ALUMINIUM OXIDES
LANTHANUM COMPOUNDS
HEAT TREATMENTS
ELECTRIC CONDUCTIVITY