Low cost, single step co-firing technique for high-performance solid oxide fuel cell fabrication

FUEL 273

Kyung Joong Yoon1, Uday B Pal, upal@bu.edu1, Srikanth Gopalan1, Wenhua Huang1, Guosheng Ye1, and Donald A Seccombe Jr., dseccombe@btu.com2. (1) Manufacturing Engineering, Boston University, 730 Commonwealth Avenue, Boston, MA 02215, (2) BTU International, 23 Esquire Road, Noth Billerica, MA 01862
For the planar solid oxide fuel cell (SOFC) based on yttria-stabilized zirconia (YSZ) electrolyte, an anode-supported structure is the preferred design and a one-step co-sintering process is the desired low-cost manufacturing process. By lowering the co-sintering temperature to below 1300C and eliminating temperature gradients within the sample and controlling the shrinkages and dimensions of the individual layers it is possible to manufacture such SOFCs. The components of the SOFCs are fabricated in the green state via tape-casting or shear compaction and repeated use of screen-printing techniques. Process parameters studied included particle size and their distribution, component thickness, type and amount of binder material used, phase distribution in the electrodes, shrinkage rates, drying time, heating and cooling rates, hold temperature and time of hold. The electrochemical performance of these cells indicated that they are capable of providing stable high power density between 0.4 to 1.5 W/cm2 while operating between 700-900C.