This study addresses the challenge of high sintering temperatures in proton-conducting fuel cells (PCFCs) with BaCeO3-doped electrolytes. We demonstrate that 1 mol% copper (Cu) doping at the B-site of BaCe0.7Zr0.1(Dy0.1|Yb0.1)0.2O3−δ (BCZDYb) improves sintering behavior, enabling densification at 1400 °C. However, Cu doping disrupts stoichiometry, creating barium vacancies and reducing proton-accepting cations, affecting overall conductivity. This mechanism is confirmed through density functional theory (DFT) calculations and various experimental techniques, including crystal structure analysis using X-ray diffraction (XRD) and morphology and elemental analysis via field emission scanning electron microscopy (FESEM) and energy-dispersive X-ray spectroscopy (EDS). Electrochemical measurements are performed using the electrochemical impedance spectroscopy (EIS). The ionic conductivity of 1 mol% Cu-doped BCZDYb (BCZDYb-1) is 1.49×10−2 S cm−1 at 650 °C, which is 3.8 times higher than that of BCZDYb sintered at 1200 °C. The BCZDYb-1 exhibits ∼3.5 times higher conductivity when sintered at 1200 °C and ∼16 times higher grain boundary conductivity when sintered at 1400 °C, compared to undoped BCZDYb. The single cell employing BCZDYb-1 as the electrolyte achieved a power density of ∼606 mW cm−2 at 550 °C. These results indicate that a controlled amount of Cu doping can enhance densification while maintaining high ionic conductivity, making it suitable for practical applications in PCFCs operating at lower temperatures.
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