Development of Low-Cost Manufacturing Processes for Planar, Multilayer Solid Oxide Fuel Cell Elements
This report summarizes the results of Phase II of this program, 'Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'. The objective of the program is to develop advanced ceramic manufacturing technologies for making planar solid oxide fuel cell (SOFC) components that are more economical and reliable for a variety of applications. Phase II development work focused on three distinct manufacturing approaches (or tracks) for planar solid oxide fuel cell elements. Two development tracks, led by NexTech Materials and Oak Ridge National Laboratory, involved co-sintering of planar SOFC elements of cathode-supported and anode-supported variations. A third development track, led by the University of Missouri-Rolla, focused on a revolutionary approach for reducing operating temperature of SOFCs by using spin-coating to deposit ultra-thin, nano-crystalline YSZ electrolyte films. The work in Phase II was supported by characterization work at Ohio State University. The primary technical accomplishments within each of the three development tracks are summarized. Track 1--NexTech's targeted manufacturing process for planar SOFC elements involves tape casting of porous electrode substrates, colloidal-spray deposition of YSZ electrolyte films, co-sintering of bi-layer elements, and screen printing of opposite electrode coatings. The bulk of NexTech's work focused on making cathode-supported elements, although the processes developed at NexTech also were applied to the fabrication of anode-supported cells. Primary accomplishments within this track are summarized below: (1) Scale up of lanthanum strontium manganite (LSM) cathode powder production process; (2) Development and scale-up of tape casting methods for cathode and anode substrates; (3) Development of automated ultrasonic-spray process for depositing YSZ films; (4) Successful co-sintering of flat bi-layer elements (both cathode and anode supported); (5) Development of anode and cathode screen-printing processes; and (6) Demonstration of novel processes for composite cathode and cermet anode materials. Track 2--ORNL's development work focused solely on making anode-supported planar cells by tape casting of a porous anode substrate, screen printing of a YSZ electrolyte film, co-sintering of the bi-layer element, and screen-printing of an opposite cathode coating. Primary accomplishments within this track are summarized below: (1) Development and scale-up of anode tape casting and lamination processes; (2) Development of proprietary ink vehicle for screen-printing processes; (3) Development of screen-printing process for depositing YSZ films; (4) Successful co-sintering of flat bi-layer anode-supported elements; and (5) Development of cathode screen-printing process. Track 3--UMR's process development work involved fabrication of a micro-porous cathode substrate, deposition of a nano-porous interlayer film, deposition of nano-crystalline YSZ electrolyte films from polymeric precursor solutions, and deposition of an anode coating. Primary accomplishments within this track are summarized below: (1) Development and scale up of tape casting and sintering methods for cathode substrates; (2) Deposition of nano-porous ceria interlayer films on cathode substrates; (3) Successful deposition of dense YSZ films on porous cathode substrates; and (4) Identification of several anode material options.
- Research Organization:
- Nextech Materials Ltd
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- AC26-00NT40706
- OSTI ID:
- 923252
- Country of Publication:
- United States
- Language:
- English
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