"Low Temperature Sintering of Ceria Barrier Layers for SOFCs"

SOFC systems are beginning to find application in markets throughout the world. Premium power products (uninterrupted power for datacenters and mobile systems for military) are providing the first market niches, while new utility strategies requiring distributed micro-grid power generation and energy storage promise excellent opportunity to product developers. To reach larger markets, SOFC systems must provide a better dollars/kilowatt ratio through performance improvements that reduce manufacturing complexity and cost. In this program, Nexceris proposes the manufacturing and performance validation of SOFC components produced using a new cathode/electrolyte interfacial layer. The proposed aerosol spray deposition approach is familiar, but the modifications to the barrier layer formulation are previously unexplored and promising. The proposed evaluation will include evaluations of established sintering aids like Co and Cu, but also less evaluated options like WO3, MoO3, and Nb2O5. Based on initial studies by Nexceris, these additives offer their own advantages for sintering improvement of ceria layers as single oxides and mixed oxide additions. Leveraging commercial powders and pilot-scale manufacturing processes, Nexceris is targeting process temperatures of 1000 ºC for the interfacial layers, with at least 10 % reduction in cathode resistance, at a manufacturing cost at least 50 % percent lower than current manufacturing costs.