Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell

Patent · Sun Jan 01 00:00:00 EST 1995

OSTI ID:869754

Kuo, Lewis J. H. ^[1]; Vora, Shailesh D ^[1]

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1. Monroeville, PA

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-x M.sub.x Cr.sub.1-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 1200.degree. to 1350.degree. 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.

• Research Organization: Westinghouse Electric Corp., Pittsburgh, PA (United States)
• DOE Contract Number: FC21-91MC28055
• Assignee: Westinghouse Electric Corporation (Pittsburgh, PA)
• Patent Number(s): US 5391440
• OSTI ID: 869754
• Country of Publication: United States
• Language: English

Related Subjects

method
forming
leak
proof
plasma
sprayed
interconnection
layer
electrode
electrochemical
cell
dense
substantially
gas-tight
electrically
conductive
formed
structure
providing
selected
portion
surface
formula
1-x
1-y
dopant
sr
mixtures
mg
independently
075-0
25
thermally
spraying
preferably
flux
added
spray
powder
agglomerated
comprising
particles
including
cao
12
lacro
undoped
form
material
bonded
single
step
heat
treating
1200
degree
1350
densify
heal
micro-cracks
macro-cracks
result
highly
doped
air
solid
electrolyte
applied
unselected
fuel
generation
electrical
power
substantially gas-tight
powder comprising
material bonded
interconnection layer
electrolyte layer
plasma spray
electrode structure
air electrode
electrical power
electrochemical cell
electrically conductive
solid electrolyte
plasma spraying
fuel electrode
electrode surface
heat treating
highly doped
interconnection material
conductive interconnection
selected portion
plasma sprayed
doped lacro
sprayed interconnection
articles including
thermally sprayed
preferably including
single plasma
conductive interconnect
leak proof
/429/29/427/