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Hierarchically oriented macroporous anode-supported solid oxide fuel cell with thin ceria electrolyte film.

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This study introduces a novel freeze-drying tape-casting method for fabricating solid oxide fuel cell (SOFC) components, significantly improving power output and reducing polarization losses for ceria-based electrolytes.

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Conversion

Background:

  • Solid oxide fuel cells (SOFCs) with ceria-based electrolytes face challenges due to high fabrication costs and electrode polarization.
  • Developing cost-effective and efficient fabrication methods for SOFC components is crucial for their commercialization.

Purpose of the Study:

  • To develop a novel fabrication method for anode-supported SOFCs with ceria-based electrolytes.
  • To improve the microstructure of NiO-GDC anodes for enhanced gas diffusion and reduced polarization.
  • To evaluate the performance of SOFCs fabricated using the new method.

Main Methods:

  • Fabrication of dense Gd0.1Ce0.9O2 (GDC) thin film electrolytes on hierarchically oriented macroporous NiO-GDC anodes using freeze-drying tape-casting and drop-coating.
  • Characterization of anode microstructure using 3D X-ray microscopy.
  • Co-firing of electrolyte/anode bilayers.
  • Performance testing of SOFCs with Ni-GDC anode, GDC electrolyte, and LSCF-GDC cathode at 600 °C using H2 fuel.
  • Electrochemical Impedance Spectroscopy (EIS) analysis.

Main Results:

  • A hierarchically oriented macroporous NiO-GDC anode microstructure with ~42% porosity and a tortuosity factor of ~1.3 was achieved.
  • SOFCs demonstrated a high power output of 1.021 W cm⁻² at 600 °C.
  • EIS analysis revealed significant reductions in both activation and concentration polarizations.

Conclusions:

  • Freeze-drying tape-casting is a highly promising approach for fabricating hierarchically oriented porous substrates for SOFCs.
  • The developed method effectively addresses limitations related to electrolyte fabrication cost and electrode polarization.
  • This advancement paves the way for more efficient and cost-effective SOFC technology.