Fabrication of 3D Ni nanosheet array on Crofer22APU interconnect and NiO-YSZ anode support to sinter with small-size Ag nanoparticles for low-temperature sealing SOFCs

A novel low-temperature sealing method was developed to seal solid oxide fuel cells. The 3D Ni nanosheet array was pre-fabricated on faying surfaces of Crofer22APU interconnect and NiO-YSZ anode-support. Then it was covered with Au film without changing its morphology. This special nanostructure improved sintering efficiency between Ag nanoparticles and substrates. A dense joint was obtained at the low-temperature between 250 °C–300 °C. This method effectively avoided the oxidation of interconnect during sealing. When joints were sealed at 300 °C, the shear strength reached 16 MPa. The fracture was mainly located in the central Ag layer, presenting a significant plastic deformation. Due to the effective protection of Ni layer, joints also possessed excellent oxidation resistance in oxidizing atmosphere at 800 °C for 400 h. After high-temperature oxidation, the shear strength was increased to 23 MPa, revealing an increasement of 43.8% compared with the as-sealed condition (16 MPa). This sealing method has great potential in sealing solid oxide fuel cells. It also can be extended to seal other energy-conversion devices.