Suspension HVOF Spraying of Reduced Temperature Solid Oxide Fuel Cell Electrolytes
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JTTEE5 17:700–707 DOI: 10.1007/s11666-008-9249-2 1059-9630/$19.00 Ó ASM International
Suspension HVOF Spraying of Reduced Temperature Solid Oxide Fuel Cell Electrolytes Jo¨rg Oberste Berghaus, J.-G. Legoux, C. Moreau, R. Hui, C. Dece`s-Petit, W. Qu, S. Yick, Z. Wang, R. Maric, and D. Ghosh (Submitted April 29, 2008; in revised form August 19, 2008) Metal-supported solid oxide fuel cells (SOFCs) composed of a Ce0.8Sm0.2O22d (SDC) electrolyte layer and Ni-Ce0.8Sm0.2O22d (Ni-SDC) cermet anode were fabricated by suspension thermal spraying on Hastelloy 3 substrates. The cathode, a Sm0.5Sr0.5CoO3 (SSCo)-SDC composite, was screen-printed and fired in situ. The anode was produced by suspension plasma spraying (SPS) using an axial injection plasma torch. The SDC electrolyte was produced by high-velocity oxy-fuel (HVOF) spraying of liquid suspension feedstock, using propylene fuel (DJ-2700). The emerging technology of HVOF suspension spraying was explored here to produce thin and low-porosity electrolytes in an effort to develop a costeffective and scalable fabrication technique for high-performance, metal-supported SOFCs. In-flight particle temperature and velocity were measured for a number of different gun operating conditions and standoff distances and related to the resulting microstructures. At optimized conditions, this approach was found to limit material decomposition, enhance deposition efficiency, and reduce defect density in the resulting coating, as compared to previous results reported with SPS. Produced button cells showed highly promising performance with a maximum power density (MPD) of 0.5 W cm22 at 600 °C and above 0.9 W cm22 at 700 °C, with humidified hydrogen as fuel and air as oxidant. The potential of this deposition technique to scale-up the substrate size to 50 3 50 mm was demonstrated.
Keywords
HVOF suspension spraying, reduced temperature solid oxide fuel cells, suspension thermal spraying
1. Introduction Solid oxide fuel cells (SOFCs) are highly efficient power converting devices combining low pollution and high fuel flexibility. The key obstacles for the widespread implementation of SOFC technology are the high component and overall manufacturing costs, which are compounded by the technical requirements of high performance, longterm stability, thermal cycling capability, and short startup This article is an invited paper selected from presentations at the 2008 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray Crossing Borders, Proceedings of the 2008 International Thermal Spray Conference, Maastricht, The Netherlands, June 2-4, 2008, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2008. Jo¨rg Oberste Berghaus, Bekaert Advanced Coatings NV, E3Laan 75-79, Deinze 9800, Belgium; J.-G. Legoux and C. Moreau, Industrial Materials Institute, NRC, Boucherville, QC, Canada; and R. Hui, C. Dece`s-Petit, W. Qu, S.
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