In this investigation, we successfully synthesized a series of Swedenborgite-type Y1-xPrxBaCo3ZnO7+δ (x = 0.0, 0.1, 0.2, 0.3, 0.4, and 0.5, abbreviated as YPxBCZ) oxides by a solid-state reaction method. The results show that YPxBCZ (x = 0.0, 0.1, 0.2, and 0.3) are single-phase structures, but YP0.4BCZ and YP0.5BCZ show interesting self-assembled composite phases. After long-term phase stability testing, YP0.3BCZ showed the best thermal stability. All samples show good chemical and thermal compatibility with La0.9Sr0.1Ga0.8Mg0.2O3-δ electrolyte. The thermal expansion coefficients in the temperature range from 30 °C to 1000 °C are equal to 9.8-13.1 × 10−6 K−1, close to that of the LSGM electrolyte. It is also found that Pr doping improves high temperature conductivity of YPxBCZ. The conductivity of YP0.3BCZ, YP0.4BCZ, and YP0.5BCZ reach 15.1, 18.5, and 22.5 S cm−1 at 800 °C. In addition, the area specific resistance (ASR) value decreases as the Pr content increases (0.038, 0.033, and 0.027 Ω cm2 at 800 °C for YP0.3BCZ, YP0.4BCZ, and YP0.5BCZ), improving the catalytic activity of the material. Another interesting finding was that the ASR of samples subjected to high temperature thermal decomposition was not adversely affected by the presence of decomposition products. The maximum power densities of YP0.3BCZ, YP0.4BCZ, and YP0.5BCZ in the single cells at 800 °C were 845, 930, and 1044 mW cm2, respectively. These results indicate that YP0.3BCZ, YP0.4BCZ, and YP0.5BCZ are promising cathode materials for intermediate-temperature solid oxide fuel cell.
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