Low Cost Materials, Designs, and Manufacturing Processes for Robust Tubular Solid Oxide Fuel Cells (SOFC)

A low cost method for manufacturing cathode SOFC tubes is proposed. This method provides more uniform properties, is easily scaled to high volume production, and is less expensive than more conventional ceramic processing methods, such as extrusion or isostatic processing. It involves preparation of a colloidal suspension of particles containing a small amount of organics, low pressure injection into a die, solidification by a temperature change, removal of tube(s) from the die, drying and firing to a temperature that provides desired properties of permeability, mechanical strength and electrical conductivity. Both short and long cathode tubes (30 inch) have been made using this process; however, neither the process nor the composition are optimized and significant improvement can be expected through the successful completion of this program