Sol-Gel Coatings as Corrosion Barriers for Carbonate Fuel Cell Components

98 Sol-gel Coatings as Corrosion Barriers for Carbonate Fuel Cell Components--Energy Research Corporation, 3 Great Pasture Road, Danbury, CT 06813-815; (203) 825-6006 Mr. Chao M. Huang, Principal Investigator Mr. Hans C. Maru, Business Official DOE Grant No. DE-FG02-97ER82402 Amount: $75,000 Carbonate fuel cell power plants offer a highly efficient and environmentally benign method of power production using natural gas or coal-derived fuels. However, the highly corrosive environment leads to shortened lifetimes for the plants¿ components. This project will utilize the recently developed sol-gel coating process to enhance endurance characteristics of the carbonate fuel cell components. The proposed coating developed in the semiconductor industry provides a low-cost means for uniform thin-film deposition on large-area complex-shaped components such as fuel cell current collectors, manifold, pipes, etc. In Phase I, feasibility of cathode dissolution retardation and cathode current collector corrosion reduction by selective coatings using the proposed process will be investigated. During this phase, out-of-cell evaluations will be conducted to determine thin file microstructure, interfacial maechanical properties, corrosion resistance and ohmic resistance. Process scale up for full-area components and stack evaluation are planned for Phase II. Commercial Applications and Other Benefits as described by the awardee: Successful demonstration of the coating on carbonate fuel cell components would provide a novel and cost effective approach to enhance the stack endurance and to accelerate commercialization of the carbonate fuel cell power plants. Successful demonstration of this coating technology will also catalyze new opportunities and market for such a coating application in chemical and energy industries that require protective coatings. _