Hybrid Manufacturing of a Single-Layer Ceramic Fuel Cell Utilizing 3D Printing and Laser Scribing

Abstract

Single-layer ceramic fuel cells are developing as a promising fuel cell technology [1-3]. Since 3D printing can create both the dense and the porous structures with good mechanical and electrochemical properties, it has the potential to revolutionize the manufacturing of fuel cells. We recently reported a 3D printed single-layer ceramic fuel cell fabricated through an extrusion-based 3D printing, which generated a power density of 230 mW/cm2 at 550oC [1]. A comprehensive investigation into the influence of sintering temperatures ranging from 700oC to 1000oC assisted us in optimizing the density of the functional layer for acceptable electrochemical performance while maintaining adequate mechanical properties. We noticed that the performance of the single-layer cells was limited by the mass transport losses due to low porosity of the single-layer. The best printed cell suffered from a high ohmic loss (0.46 Ω.cm2) and a polarization loss (0.32 Ω.cm2) [1]. In this work, we used a hybrid of a 3D printer and a laser scriber to fabricate the patterned single-layer ceramic fuel cells. Interestingly, the performance of the patterned single-layer ceramic fuel cell was 30% better as compared to a conventional single-layer fuel cell without any patterns. The patterned structures on the surfaces of the cell obtained through the laser scribing, considerably improved the electrode processes. In the patterned 3D printed fuel cells, we studied several electrode materials such as CuFe2O4, LSCF, LSC, NiCoAlLi-oxide, and LiNiZn-oxide and synthesized pastes appropriate for extrusion-based 3D printing. The rheological characteristics of the pastes were investigated using several characterization techniques such as dynamic light scattering, viscometry and tensiometry. Electrochemical impedance spectroscopy and current-voltage measurements were used to assess the electrochemical performance of the cells. Furthermore, high-temperature XRD demonstrated the composite materials' excellent structural stability. To further understand the processes in the cells, additional spectroscopic and microscopic investigations (HR-TEM, SEM-EDX, XPS) were performed. Acknowledgement. Dr. Asghar thanks Academy of Finland (Grant No. 13322738, 13329016) and the Hubei overseas Talent 100 program for their support.