skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report

Abstract

The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect ofmore » the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.« less

Authors:
; ;
Publication Date:
Research Org.:
Westinghouse Electric Corp., Pittsburgh, PA (United States). Advanced Energy Conversion Dept.
Sponsoring Org.:
USDOE, Washington, DC (United States)
OSTI Identifier:
10169590
Report Number(s):
DOE/MC/25167-2986
ON: DE91002066
DOE Contract Number:  
AC21-88MC25167
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: Jul 1991
Country of Publication:
United States
Language:
English
Subject:
30 DIRECT ENERGY CONVERSION; SOLID ELECTROLYTE FUEL CELLS; COATINGS; PLASMA ARC SPRAYING; PARAMETRIC ANALYSIS; PROGRESS REPORT; OXIDES; FABRICATION; ELECTRIC CONDUCTIVITY; STABILITY; PERFORMANCE TESTING; CONNECTORS; 300501; 300502; DESIGN AND DEVELOPMENT; PERFORMANCE AND TESTING

Citation Formats

Ray, E R, Spengler, C J, and Herman, H. Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report. United States: N. p., 1991. Web. doi:10.2172/10169590.
Ray, E R, Spengler, C J, & Herman, H. Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report. United States. https://doi.org/10.2172/10169590
Ray, E R, Spengler, C J, and Herman, H. 1991. "Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report". United States. https://doi.org/10.2172/10169590. https://www.osti.gov/servlets/purl/10169590.
@article{osti_10169590,
title = {Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report},
author = {Ray, E R and Spengler, C J and Herman, H},
abstractNote = {The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect of the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.},
doi = {10.2172/10169590},
url = {https://www.osti.gov/biblio/10169590}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Jul 01 00:00:00 EDT 1991},
month = {Mon Jul 01 00:00:00 EDT 1991}
}