Low-pressure plasma sprayed dense scandia-stabilized zirconia electrolyte and its effect on SOFC performance

Abstract

The plasma spraying process has been proven capable of fabricating high-performance metal-supported solid oxide fuel cells (MS-SOFCs), and the critical technology is to prepare dense MS-SOFC electrolytes. Usually, very low-pressure plasma spraying (<1000 Pa) is adopted as it can significantly improve the electrolyte density and air tightness. However, at the same time, it also has the disadvantages of low deposition efficiency and high cost. This paper explores whether it is possible to prepare dense MS-SOFC electrolytes under low-pressure conditions (1000–10000 Pa) with ideal deposition efficiency and cost. Specifically, 4000 Pa and 7000 Pa were chosen to prepare scandia-stabilized zirconia (ScSZ) electrolytes. The effects of spraying pressure and distance on the electrolyte microstructure and cell electrochemical performance were investigated. It was found that the electrolyte prepared at a pressure of 4000 Pa and a spraying distance of 325 mm had the lowest porosity of 3.28%. Meanwhile, the cell exhibited the best electrochemical performance with an open circuit voltage of 1.008 V and a maximum power density of 970 mW/cm2 at 800 °C.