Multilayer tape casting of large-scale anode-supported thin-film electrolyte solid oxide fuel cells

Abstract

Tape casting is conventionally used to prepare individual, relatively thick components (i.e., the anode or electrolyte supporting layer) for solid oxide fuel cells (SOFCs). In this research, a multilayer ceramic structure is prepared by sequentially tape casting ceramic slurries of different compositions onto a Mylar carrier followed by co-sintering at 1400 °C. The resulting half-cells contains a 300 μm thick NiO–yttria-stabilized zirconia (YSZ) anode support, a 20 μm NiO–YSZ anode functional layer, and an 8 μm YSZ electrolyte membrane. Complete SOFCs are obtained after applying a Gd0.1Ce0.9O2 (GDC) barrier layer and a Sm0.5Sr0.5CoO3 (SSC) -GDC cathode by using a wet-slurry spray method. The 50 mm × 50 mm SOFCs produce peak power densities of 337, 554, 772, and 923 mW/cm2 at 600, 650, 700, and 750 °C, respectively, on hydrogen fuel. A short stack including four 100 mm × 150 mm cells is assembled and tested. Each stack repeat unit (one cell and one interconnect) generates around 28.5 W of electrical power at a 300 mA/cm2 current density and 700 °C.