Mathematical Model-Assisted Ultrasonic Spray Coating for Scalable Production of Large-Sized Solid Oxide...

Area of Science:

• Materials Science
• Electrochemistry
• Chemical Engineering

Background:

• Thin solid oxide films are vital for solid oxide-based electrochemical devices used in decarbonization.
• Ultrasonic spray coating (USC) offers scalable production advantages for these films.
• Previous USC parameter optimizations lack systematic and practical approaches for large-scale manufacturing.

Purpose of the Study:

• To develop a systematic and facile USC parameter optimization process assisted by mathematical models.
• To achieve optimal settings for producing high-quality, uniform thin oxide films for electrochemical devices.
• To validate the performance of USC-fabricated components in protonic ceramic electrochemical cells.

Main Methods:

• Mathematical modeling to assist ultrasonic spray coating (USC) parameter optimization.
• Systematic optimization of USC parameters for thin oxide film deposition.
• Fabrication and performance testing of protonic ceramic electrochemical cells using USC-deposited components.

Main Results:

• Optimal USC settings were identified, producing uniform 4 × 4 cm² oxygen electrode films (∼27 μm thickness) in 1 minute.
• Films met desirable thickness and uniformity criteria at both micrometer and centimeter scales.
• USC-fabricated cells achieved 0.88 W cm^-2 peak power density (fuel cell mode) and 1.36 A cm^-2 at 1.3 V (electrolysis mode) with 200 h stability.

Conclusions:

• The proposed USC optimization process is systematic, facile, and practical for scalable production of thin oxide films.
• USC is a promising technology for manufacturing large-sized solid oxide electrochemical cells for decarbonization applications.
• High-performance protonic ceramic electrochemical cells demonstrate the efficacy of USC-fabricated components.