Advanced Thermal Spray Fabrication of Solid Oxide Fuel Cells

73154B03-I Solid Oxide Fuel Cell (SOFC) technology is expected to revolutionize power generation in the coming decades due to its higher energy efficiency, improved environmental performance and cost. The main impediment to SOFC implementation on a large scale is cell manufacturing cost. This is due to the complex requirements of a dynamic multi-layer system and the integration of advanced materials into the cell. Thermal spray is a versatile, efficient, and cost effective approach to produce the ceramic fuel cell multilayers. However, conventional thermal spray is not suited to meet the requirements of a modern fuel cell design. This is due to the lack of effective microstructural control, interconnected porosity in electrolytes, and poor material utilization during deposition. This project will develop advanced thermal spray methods for the fabrication of the fuel cell layers, especially the electrolyte. Phase I will focus on integrated planning for design, materials, and processes to assess issues in the spray deposition of SOFCs. Both cathodic and anodic substrates will be developed as platforms for electrolyte deposition using advanced thermal spray. Through iterative microstructural characterization and performance assessment, key strategies for cell fabrication will be identified. Complete cell fabrication will be undertaken in Phase II. Commercial Applications and Other Benefits as described by awardee: Successful implementation of thermal spray based SOFC technology should provide important benefits to the SOFC development industry and the energy sector as a whole. Other possible applications include membrane gas separation, metal refining etc.