Low Cost Spray-On Coatings for Protection of SOFC Interconnects and BOP Components

Solid Oxide Fuel Cells (SOFCs) present one of the most promising choices for the future of distributed power generation as they produce energy from a wide variety of fuels with high efficiencies (45-65 %) and low pollution; however, this technology is cost prohibitive and not widely used. The use of ferritic steels in SOFCs can decrease cost, but degradation of these materials due to elevated temperature (600-1000 oC), dual reducing and oxidizing atmospheres, and water vapor present during operation necessitates the development of innovative solutions to provide durable oxidation protection and mitigation of Cr volatilization. Current solutions involve the use of specialty alloys or coatings that are often expensive, ineffective, or impractical for SOFC components. New coating technologies are necessary to enable lower cost and widespread use of SOFCs. With the ultimate goal of decreasing cost to enable the widespread use of Solid Oxide Fuels Cells (SOFCs), nGimat Co. proposes the use of NanoSpraySM Combustion Chemical Vapor Deposition (CCVD) for the flame spray application of coatings intended to protect SOFC stainless steel interconnects and Balance of Plant (BOP) components against oxidation, corrosion, and metal loss that leads to increased cost as well as decreased SOFC lifetime and performance. NanoSpraySM CCVD technology enables the fabrication of layers similar to high vacuum vapor deposited coatings but with a low cost and open atmosphere process that does not require post deposition heat treatment. Other advantages of this unique technology include the ability to easily tailor or alter composition to form nanolaminates through a one step process that can be readily integrated into a production line and adapted for roll-to-roll (R2R) fabrication. nGimat Co. test results show that CCVD formed nanolaminate technology does increase the lifetime and durability of stainless steels used for SOFC components as well as other metals in high temperature environments while being lower cost than other thin film coating processes which is important to enable widespread use of SOFCs. Commercial Applications and Other Benefits SOFCs present a promising option for efficient and nearly pollution free energy production. In order for this promise to be realized, innovative solutions that advance SOFCs and reduce costs are necessary. The proposed use of NanoSpraySM CCVD for SOFC applications is an example of a technological innovation that will help advance fuel cells. The direct and indirect anticipated public benefits from the development of this technology include: Decreased SOFC cost, Increased SOFC lifetime and reliability Decreased negative environmental impact, Decreased dependence on imported fossil fuels , Creation of new jobs.