Thin-film solid oxide fuel cells (TF-SOFCs) are an attractive renewable energy source due to their high efficiency, increased power output and ability to be efficiently stacked for power generation at a small or large-scale. [N. Q. Minh, J Am Ceram Soc. 1993; 76(3):563-588.] Nanoporous Al2O3, also known as anodized aluminum oxide (AAO) is an appropriate substrate for TF-SOFCs due to its high temperature stability, chemically inert nature, and porosity that allows gas flow to the anode. The aligned, nano-sized pores allow for both conformal sputtering on the surface and efficient fuel delivery to the anode, making it particularly suited for thin film deposition. Electroless nickel plating is used to achieve a fully conductive, nanoporous substrate which catalyzes the hydrogen oxidation reaction and improves current collection efficiency in TF-SOFCs. A minimum plating temperature of 60°C is needed to grow nanoscale Ni deposits into a conductive film without compromising the porosity of the surface. Effective stirring methods are used to deliver the plating solution throughout the high-aspect ratio pores of the AAO substrate and create thru-plane conductivity. To achieve conformal plating, the number of pre-treatment steps was optimized to prevent overplating and create a homogenous Ni deposit. Finally, with the creation of a conformally coated, conductive porous substrate, we can improve the efficiency and power output of TF-SOFC performance with commercially relevant active areas (larger than 1 cm2).
Read full abstract