Relationship Between Particle and Plasma Properties and Coating Characteristics of Samaria-Doped Ceria Prepared by Atmos
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JTTEE5 21:448–460 DOI: 10.1007/s11666-012-9742-5 1059-9630/$19.00 ASM International
Relationship Between Particle and Plasma Properties and Coating Characteristics of Samaria-Doped Ceria Prepared by Atmospheric Plasma Spraying for Use in Solid Oxide Fuel Cells Mark Cuglietta and Olivera Kesler (Submitted September 15, 2011; in revised form December 19, 2011) Samaria-doped ceria (SDC) has become a promising material for the fabrication of high-performance, intermediate-temperature solid oxide fuel cells (SOFCs). In this study, the in-flight characteristics, such as particle velocity and surface temperature, of spray-dried SDC agglomerates were measured and correlated to the resulting microstructures of SDC coatings fabricated using atmospheric plasma spraying, a manufacturing technique with the capability of producing full cells in minutes. Plasmas containing argon, nitrogen and hydrogen led to particle surface temperatures higher than those in plasmas containing only argon and nitrogen. A threshold temperature for the successful deposition of SDC on porous stainless steel substrates was calculated to be 2570 °C. Coating porosity was found to be linked to average particle temperature, suggesting that plasma conditions leading to lower particle temperatures may be most suitable for fabricating porous SOFC electrode layers.
Keywords
anode, atmospheric plasma spraying, deposition efficiency, samaria-doped ceria, SDC, SOFC, solid oxide fuel cell
1. Introduction Solid oxide fuel cells (SOFCs) offer a promising alternative to conventional power generation technologies because of their inherently high operating efficiency and low pollution emissions. Currently, the cost of manufacturing cells and their low durability has limited the widespread use of this technology, and much effort has been spent recently in an attempt to reduce their production cost and increase their lifetime.
This article is an invited paper selected from presentations at the 2011 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2011: Proceedings of the International Thermal Spray Conference, Hamburg, Germany, September 27-29, 2011, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Andre´ McDonald, Ed., ASM International, Materials Park, OH, 2011. Mark Cuglietta and Olivera Kesler, Department of Mechanical and Industrial Engineering, University of Toronto, 5 KingÕs College Road, Toronto, ON M5S 3G8, Canada. Contact e-mail: [email protected], [email protected].
448—Volume 21(3-4) June 2012
Atmospheric plasma spraying (APS), a form of thermal spraying technology, has been identified as a potential cost-reducing manufacturing technique for SOFCs because it has been proven to be able to produce a full cell in minutes, and it facilitates the use of relatively inexpensive ferritic stainless steel supporting structures (Ref 1, 2). A consequence of using metal supports is that metalsupported SOFC
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