Abstract
This study was aimed at developing an integrated fabrication process for solid oxide fuel cells (SOFC) with radio-frequency plasma spraying (RFPS) and/or hybrid plasma spraying (HYPS). Fundamental studies concerning particle velocity and deformation showed that the novel plasma spraying processes were mainly characterized by their superior capability for homogeneous heating and spraying of large size powders with relatively low particle velocity, and that even the lower particle velocities in RFPS (20 m s-1) and HYPS (40-70 m s-1) compared with those in direct current plasma spraying (200 m s-1) were found to be sufficient for deformation of impinging molten particles on the substrate. However, RFPS imposed as a severe limitation on the substrate position because it led to a short flying distance for the molten particles. In this respect, HYPS was considered to be superior to RFPS.
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