Electrode-supported solid oxide cell (SOC) performance, efficiency, and stability are largely dependent on their Ni-YSZ cermet electrodes and supports. The design variables for these Ni-YSZ layers include the Ni/YSZ ratio, pore former volume fraction/size, thicknesses, and the firing conditions that partly determine their microstructures. These parameters can be used to optimize the electrode by maximizing active triple phase boundary (TPB) density in the functional layer, maximizing gas transport through the support, achieving required conductivity, maintaining mechanical strength, and minimizing overall Ni content.This study aims to investigate how Ni-YSZ characteristics affect overall electrochemical performance and mechanical strength. In the initial studies, Ni-YSZ electrode-supported symmetric cells with a single uniform Ni-YSZ layer without pore former were studied to focus on functional layer properties. Cells with different Ni contents were compared. Cells were manufactured by laminating tape-cast layers and co-sintering at high temperatures, with a YSZ electrolyte thickness of ~ 10 μm and Ni-YSZ thickness of ~ 150 μm. Initial NiO weight percentages in the NiO-YSZ slurries were varied from 45 to 70% in different cells. Although NiO-YSZ layers with different compositions are expected to have different shrinkages, we found that by sintering the symmetric cells at 1300°C, all cell configurations were free of defects, curvature, or delamination.Flexural strengths of both the electrodes and symmetric cells were characterized at ambient temperature via three-point bending tests. The NiO-YSZ composite reduction to cermet Ni-YSZ decreases flexural strength. In addition, increases in Ni content decrease flexural strength. The flexural strength results will be compared with values expected based on classic laminate plate theory.Electrochemical impedance spectroscopy measurements were taken at open circuit voltage in 97% H2-3% H2O at 650°C, 700°C, 750°C, and 800°C. The impedance results fitted well using an equivalent circuit model that includes Ohmic, transmission line, and Warburg resistance elements. The Warburg resistance, which corresponds to gas diffusion processes, decreases significantly with increasing Ni content since most of the porosity results from the reduction of NiO to Ni. In these low steam conditions, the Warburg resistance element dominates overall impedance in 45 to 65 NiO weight percent electrodes. The 50-weight percent NiO electrode was found to minimize transmission line model resistance. The correlation between impedance results and the measured electrode microstructure (e.g., porosity, tortuosity, and active TPB density) will be discussed.
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