Innovative, Laser-Based Process for Development and Manufacturing of Solid Oxide Fuel Cells

Abstract

A novel, versatile, scalable and economical laser-pyrolysis based process for high performance solid oxide fuel cells (SOFCs), interconnects and seals is described. The Laser Reactive Deposition (LRD ) process converts low cost metal precursors into SOFC layers; thus eliminating the need to undertake powder synthesis, calcining, ball milling, batch formulation, slurry preparation, tape formation, and binder burnout steps required in conventional SOFC cell fabrication. By simplifying the manufacturing process, the LRD route achieves low SOFC stack manufacturing cost at low volumes, simplifies footprint and throughput scale-up, and dramatically compresses materials and components development cycles, thus accelerating commercialization and market growth. Results from initial efforts to synthesize conventional SOFC layers (Ni-8YSZ anode, 8YSZ electrolyte, and Sr-doped LaMnO 3 cathode) by the LRD route from mixtures of the respective metal nitrates are described. The layers fabricated on 8YSZ substrates using the LRD approach are of the desired phase with crystallite sizes in the nanoscale region, even after sintering at high temperatures.