Development of vacuum plasma sprayed thin-film SOFC for reduced operating temperature

Abstract

The reduction of the operating temperature of planar solid oxide fuel cells (SOFCs) to an intermediate temperature regime of 650–800°C is an important objective in current development activities worldwide, in order to reduce production costs and improve long-term stability. In addition, existing conventional SOFC production processes must be further developed towards automated production lines, and new manufacturing processes with the potential for mass production must be established to meet the strict cost targets for the successful introduction of SOFCs in the strongly competitive energy market. DLR the German aerospace research centre has developed a novel planar thin-film SOFC concept which is based on advanced plasma spray processes. These manufacturing techniques allow the subsequent deposition of the entire membrane-electrode assembly (MEA) onto a porous metallic substrate within a very short process time, and has the potential to be developed into an automated continuous production process. By applying the plasma spray technology single cells were fabricated and characterised as having high performance in the temperature range 750–900°C and good long-term behaviour. Further development work will concentrate on the assembly of stacks with several large-scale cells with dimensions of 10 × 10 and 20 × 20 cm 2 , in order to obtain stack performance and durability results.