A promising NiCo2O4 protective coating for metallic interconnects of solid oxide fuel cells

The NiCo₂O₄ spinel coating is applied onto the surfaces of the SUS 430 ferritic stainless steel by the sol-gel process; and the coated alloy, together with the uncoated as a comparison, is cyclically oxidized in air at 800 °C for 200 h. The oxidation behavior and oxide scale microstructure as well as the electrical property are characterized. The results indicate that the oxidation resistance is significantly enhanced by the protective coating with a parabolic rate constant of 8.1 × 10⁻¹⁵ g² cm⁻⁴ s⁻¹, while the electrical conductivity is considerably improved due to inhibited growth of resistive Cr₂O₃ and the formation of conductive spinel phases in the oxide scale.     

Fabrication and characterization of a co-fired La0.6Sr0.4Co0.2Fe0.8O3−δ cathode-supported Ce0.9Gd0.1O1.95 thin-film for IT-SOFCs

A dense membrane of Ce_0.9Gd_0.1O_1.95 on a porous cathode based on a mixed conducting La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ was fabricated via a slurry coating/co-firing process. With the purpose of matching of shrinkage between the support cathode and the supported membrane, nano-Ce_0.9Gd_0.1O_1.95 powder with specific surface area of 30 m² g⁻¹ was synthesized by a newly devised coprecipitation to make the low-temperature sinterable electrolyte, whereas 39 m² g⁻¹ nano-Ce_0.9Gd_0.1O_1.95 prepared from citrate method was added to the cathode to favor the shrinkage for the La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ. Bi-layers consisting of <20 μm dense ceria film on 2 mm thick porous cathode were successfully fabricated at 1200 °C. This was followed by co-firing with NiO–Ce_0.9Gd_0.1O_1.95 at 1100 °C to form a thin, porous, and well-adherent anode. The laboratory-sized cathode-supported cell was shown to operate below 600 °C, and the maximum power density obtained was 35 mW cm⁻² at 550 °C, 60 mW cm⁻² at 600 °C.     

CoFe2O4 spinel protection coating thermally converted from the electroplated Co-Fe alloy for solid oxide fuel cell interconnect application

CoFe₂O₄ has been demonstrated as a potential spinel coating for protecting the Cr-containing ferritic interconnects. This spinel had an electrical conductivity of 0.85 S cm⁻¹ at 800 °C in air and an average coefficient of thermal expansion (CTE) of 11.80 × 10⁻⁶ K⁻¹ from room temperature to 800 °C. A series of Co-Fe alloys were co-deposited onto the Crofer 22 APU ferritic steel via electroplating with an acidic chloride solution. After thermal oxidation in air at 800 °C, a CoFe₂O₄ spinel layer was attained from the plated Co_0.40Fe_0.60 film. Furthermore, a channeled Crofer 22 APU interconnect electrodeposited with a 40-μm Co_0.40Fe_0.60 alloy film as a protective coating was evaluated in a single-cell configuration. The presence of the dense, Cr-free CoFe₂O₄ spinel layer was effective in blocking the Cr migration/transport and thus contributed to the improvement in cell performance stability.     

Evaluation of Ni80Cr20/(La0.75Sr0.25)0.95MnO3 dual layer coating on SUS 430 stainless steel used as metallic interconnect for solid oxide fuel cells

Ni₈₀Cr₂₀/(La_0.75Sr_0.25)_0.95MnO₃ dual-layer coating is deposited on SUS 430 alloy by plasma spray for solid oxide fuel cell (SOFC) interconnect application. The phase structure, area specific resistance (ASR), and morphology of the coating are studied. A two-cell stack is also assembled and tested to evaluate coating performance in an actual SOFC stack. The NiCr/LSM coating adheres well to the SUS 430 alloy after oxidation in air at 800 °C for 2800 h. The ASR and its increasing rate of coated alloy are 25 mΩ cm² and 0.0017 mΩ cm²/h, respectively. In an actual stack test, the maximum output power density of the stack repeating unit increases from 0.32 W cm⁻² to 0.45 W cm⁻² because of the application of NiCr/LSM coating. The degradation rate of the stack repeating unit with no coating is 4.4%/100 h at a current density of 0.36 A cm⁻², whereas the stack repeating unit with NiCr/LSM coating exhibits no degradation. Ni₈₀Cr₂₀/(La_0.75Sr_0.25)_0.95MnO₃ dual-layer coating can remarkably improve the thermal stability and electrical performance of metallic interconnects for SOFCs.     

Ba0.5Sr0.5Co0.8Fe0.2O3 − δ + LaCoO3 composite cathode for Sm0.2Ce0.8O1.9-electrolyte based intermediate-temperature solid-oxide fuel cells

A novel Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3 − δ + LaCoO₃ (BSCF + LC) composite oxide was investigated for the potential application as a cathode for intermediate-temperature solid-oxide fuel cells based on a Sm_0.2Ce_0.8O_1.9 (SDC) electrolyte. The LC oxide was added to BSCF cathode in order to improve its electrical conductivity. X-ray diffraction examination demonstrated that the solid-state reaction between LC and BSCF phases occurred at temperatures above 950 °C and formed the final product with the composition: La_0.316Ba_0.342Sr_0.342Co_0.863Fe_0.137O_3 − δ at 1100 °C. The inter-diffusion between BSCF and LC was identified by the environmental scanning electron microscopy and energy dispersive X-ray examination. The electrical conductivity of the BSCF + LC composite oxide increased with increasing calcination temperature, and reached a maximum value of ∼300 S cm⁻¹ at a calcination temperature of 1050 °C, while the electrical conductivity of the pure BSCF was only ∼40 S cm⁻¹. The improved conductivity resulted in attractive cathode performance. An area-specific resistance as low as 0.21 Ω cm² was achieved at 600 °C for the BSCF (70 vol.%) + LC (30 vol.%) composite cathode calcined at 950 °C for 5 h. Peak power densities as high as ∼700 mW cm⁻² at 650 °C and ∼525 mW cm⁻² at 600 °C were reached for the thin-film fuel cells with the optimized cathode composition and calcination temperatures.     

Preparation of supported SrCeO3-based membrane by spin coating method

SrCe_0.9Y_0.1O_3−δ (SCY10) powder with a pure perovskite phase is prepared by solid-state reaction method. NiO is dispersed uniformly in SCY10 powder to fabricate NiO-SCY10 anode substrate. The starting powder, the mixture of SrCO₃, CeO₂ and Y₂O₃, is deposited directly on the green substrate instead of SCY10 powder by spin coating. After co-firing at 1300 °C for 3 h, the starting powder reacts to form SCY10 top layer on the substrate. SEM micrographs show that the top layer is defect-free and adheres well with the anode substrate without any delamination. A single fuel cell is assembled with anode-supported SCY10 membrane as electrolyte membrane and Ag as cathode. The electrochemical property of the fuel cell is tested with hydrogen as fuel in the temperature range of 600-800 °C. The open circuit voltage (OCV) reaches 1.05 V at 800 °C, and the maximum power density is 50 mW cm⁻², 155 mW cm⁻², 200 mW cm⁻² at 600 °C, 700 °C, 800 °C, respectively.     

Preparation of manganese oxide with high density by decomposition of MnCO3 and its application to synthesis of LiMn2O4

Manganese oxide with high tap density was prepared by decomposition of spherical manganese carbonate, and then LiMn₂O₄ cathode materials were synthesized by solid-state reaction between the manganese oxide and lithium carbonate. Structure and properties of the samples were determined by X-ray diffraction, Brunauer–Emmer–Teller surface area analysis, scanning electron microscope and electrochemical measurements. With increase of the decomposition temperature from 350 °C to 900 °C, the tap density of the manganese oxide rises from 0.91 g cm⁻³ to 2.06 g cm⁻³. Compared with the LiMn₂O₄ cathode made from chemical manganese dioxide or electrolytic manganese dioxide, the LiMn₂O₄ made from manganese oxide of this work has a larger tap density (2.53 g cm⁻³), and better electrochemical performances with an initial discharge capacity of 117 mAh g⁻¹, a capacity retention of 93.5% at the 15th cycle and an irreversible capacity loss of 2.24% after storage at room temperature for 28 days.     

Investigation on silver electric adhesive doped with Al2O3 ceramic particles for sealing planar solid oxide fuel cell

The silver electric adhesive doped with Al₂O₃ ceramic particles is used as sealing material for planar solid oxide fuel cell (SOFC). The sealing temperature of this sealing material is 600 °C with the heating rate of 2 °C min⁻¹, and the minimal leak rate ranges from 0.030 sccm cm⁻¹ to 0.040 sccm cm⁻¹. When doping 15 mass% Al₂O₃ ceramic particles into this sealing material, the thermal expansion coefficient of this material decreases from 20 ppm K⁻¹ to 15 ppm K⁻¹, which improves the thermal matching performance and the long-term stability of the material significantly. When using the gradient sealing method with the pure silver electric adhesive and the silver electric adhesive doped with Al₂O₃ ceramic particles to seal the interface of Ni-YSZ/SUS430 in the simulating cell, the minimal leak rate of 0.035 sccm cm⁻¹ is obtained for the cell. Furthermore, the simulating cell sealed with the compound silver electric adhesive presents good heat-resistant impact ability. Therefore, this compound sealing technique is a very promising sealing method for SOFC.     

Cyclic oxidation of Mn–Co spinel coated SUS 430 alloy in the cathodic atmosphere of solid oxide fuel cells

In order to improve oxidation resistance and long-term stability of the metallic interconnects and prevent the cathode of solid oxide fuel cells (SOFCs) from Cr-poisoning, an effective, relatively dense and well adherent Mn–Co spinel protection coating with a nominal composition of MnCo₂O₄ is applied onto the surfaces of the SUS 430 ferritic stainless steel by a cost-effective sol–gel process. The long-term thermally cyclic oxidation kinetics and oxide scale structures as well as the composition of the coated SUS 430 alloy are investigated. The Mn–Co spinel protection layer demonstrates an excellent structural and thermomechanical stability, and effectively acts as a mass barrier to the outward diffusion of cations, especially Cr, and a lowered parabolic rate constant of k_p = 1.951 × 10⁻¹⁵ g² cm⁻⁴ s⁻¹ is obtained.     

Novel Al2O3-based compressive seals for IT-SOFC applications

Novel compressive Al₂O₃-based seals were developed and characterized under simulated intermediate temperature solid oxide fuel cell (IT-SOFC) environment. The seals were prepared by tape casting, mainly composed of fine Al₂O₃ powder with various contents of fine Al powder addition. The leakage rates were determined at 800 °C under 0.14–0.69 MPa compressive stresses, and the stabilities were evaluated at 750 °C under constant 0.35 MPa compressive stress. The leakage rates at 800 °C were in range of 0.2–0.01 sccm cm⁻¹, decreasing with increasing the compressive stress and Al content; Al addition significantly improved the stability, the leakage rate with 20 wt% Al addition was as low as 0.025 sccm cm⁻¹ at 800 °C under 0.35 MPa compressive stress with a gauge pressure of 6.9 kPa, and exhibited good stability at 750 °C. Single cell test also confirmed the effectiveness of the tape cast Al₂O₃-based seal for planar IT-SOFC applications.     

Electrochemical performance of (Ba0.5Sr0.5)0.9Sm0.1Co0.8Fe0.2O3−δ as an intermediate temperature solid oxide fuel cell cathode

This study presents the electrochemical performance of (Ba_0.5Sr_0.5)_0.9Sm_0.1Co_0.8Fe_0.2O_3−δ (BSSCF) as a cathode material for intermediate temperature solid oxide fuel cells (IT-SOFC). AC-impedance analyses were carried on an electrolyte supported BSSCF/Sm_0.2Ce_0.8O_1.9 (SDC)/Ag half-cell and a Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF)/SDC/Ag half-cell. In contrast to the BSCF cathode half-cell, the total resistance of the BSSCF cathode half-cell was lower, e.g., at 550 °C; the values for the BSSCF and BSCF were 1.54 and 2.33 Ω cm², respectively. The cell performance measurements were conducted on a Ni-SDC anode supported single cell using a SDC thin film as electrolyte, and BSSCF layer as cathode. The maximum power densities were 681 mW cm⁻² at 600 °C and 820 mW cm⁻² at 650 °C.     

Iron oxide (n-Fe2O3) nanowire films and carbon modified (CM)-n-Fe2O3 thin films for hydrogen production by photosplitting of water

Iron oxide n-Fe₂O₃ nanowire photoelectrodes were synthesized by thermal oxidation of Fe metal sheet (Alfa Co. 0.25 mm thick) in an electric oven then tested for their photoactivity. The photoresponse of the n-Fe₂O₃ nanowires was evaluated by measuring the rate of water splitting reaction to hydrogen and oxygen, which is proportional to photocurrent density, J_p. The optimized electric oven-made n-Fe₂O₃ nanowire photoelectrodes showed photocurrent densities of 1.46 mA cm⁻² at measured potential of 0.1 V/SCE at illumination intensity of 100 mW cm⁻² from a Solar simulator with a global AM 1.5 filter. For the optimized carbon modified (CM)-n-TiO₂ synthesized by thermal flame oxidation the photocurrent density for water splitting was found to increase by two fold to 3.0 mA cm⁻² measured at the same measured potential and the illumination intensity. The carbon modified (CM)-n-Fe₂O₃ electrode showed a shift of the open circuit potential by −100 mV/SCE compared to undoped n-Fe₂O₃ nanowires. A maximum photoconversion efficiency of 2.3% at applied potential of 0.5 V/E_aoc was found for CM-n-Fe₂O₃ compared to 1.69% for n-Fe₂O₃ nanowires at higher applied potential of 0.7 V/E_aoc. These CM-n- Fe₂O₃ and n- Fe₂O₃ nanowires thin films were characterized using photocurrent density measurements under monochromatic light illumination, UV-Vis spectra, X-ray diffraction (XRD) and scanning electron microscopy (SEM).     

Correlation between electrical properties and microstructure of nanocrystallized V2O5-P2O5 glasses

It was shown that by thermal nanocrystallization of a 90V₂O₅·10P₂O₅ glass one can obtain a novel nanomaterial exhibiting enhanced electronic conductivity. Using a combination of methods: DTA, SEM, XRD and impedance spectroscopy (IS), it was possible to find correlation between microstructure and electrical properties of the obtained material and to optimize conditions of its synthesis. The room temperature electronic conductivity of the nanocrystallized samples is σ₂₅ = 2 × 10⁻³ S cm⁻¹ and is by a factor of 25 higher than the conductivity of the as-received glass. The nanocrystallized material is thermally stable up to ca 400 °C, which is about 150 °C above the glass transition temperature of the original glass. Maximum electronic conductivity of the thermally treated samples reaches 2 × 10⁻¹ S cm⁻¹ at ca 400 °C. The activation energy for these samples (0.28 eV) are substantially lower than that found for the starting glass (0.34 eV). The experimental results were discussed in terms of a model proposed in this paper and based on a “core-shell” concept. The results obtained here can be important for the progress in the search of novel nanocrystalline cathode materials for applications in Li-ion batteries.     

Improved high temperature performance of La0.8Sr0.2MnO3 cathode by addition of CeO2

Ceria is proposed as an additive for La_0.8Sr_0.2MnO₃ (LSM) cathodes in order to increase both their thermal stability and electrochemical properties after co-sintering with an yttria-stabilized zirconia (YSZ) electrolyte at 1350 °C. Results show that LSM without CeO₂ addition is unstable at 1350 °C, whereas the thermal stability of LSM is drastically improved after addition of CeO₂. In addition, results show a correlation between CeO₂ addition and the maximum power density obtained in 300 μm thick electrolyte-supported single cells in which the anode and modified cathode have been co-sintered at 1350 °C. Single cells with cathodes not containing CeO₂ produce only 7 mW cm⁻² at 800 °C, whereas the power density increases to 117 mW cm⁻² for a CeO₂ addition of 12 mol%. Preliminary results suggest that CeO₂ could increase the power density by at least two mechanisms: (1) incorporation of cerium into the LSM crystal structure, and (2) by modification or reduction of La₂Zr₂O₇ formation at high temperature. This approach permits the highest LSM-YSZ co-sintering temperature so far reported, providing power densities of hundreds of mW cm⁻² without the need for a buffer layer between the LSM cathode and YSZ electrolyte. Therefore, this method simplifies the co-sintering of SOFC cells at high temperature and improves their electrochemical performance.     

Electrochemical deposition of porous Co3O4 nanostructured thin film for lithium-ion battery

Porous Co₃O₄ nanostructured thin films are electrodeposited by controlling the concentration of Co(NO₃)₂ aqueous solution on nickel sheets, and then sintered at 300 °C for 3 h. The as-prepared thin films are characterized by thermogravimetric analysis (TGA), X-ray diffraction (XRD), and scanning electron microscopy (SEM). The electrochemical measurements show that the highly porous Co₃O₄ thin film with the highest electrochemically active specific surface area (68.64 m² g⁻¹) yields the best electrochemical performance compared with another, less-porous film and with a non-porous film. The highest specific capacity (513 mAh g⁻¹ after 50 cycles) is obtained from the thinnest film with Co₃O₄ loaded at rate of 0.05 mg cm⁻². The present research demonstrates that electrode morphology is one of the crucial factors that affect the electrochemical properties of electrodes.     

Effects of roasting temperature and modification on properties of Li2FeSiO4/C cathode

Li₂FeSiO₄/C cathodes were synthesized by combination of wet-process method and solid-state reaction at high temperature, and effects of roasting temperature and modification on properties of the Li₂FeSiO₄/C cathode were investigated. The XRD patterns of the Li₂FeSiO₄/C samples indicate that all the samples are of good crystallinity, and a little Fe₃O₄ impurity was observed in them. The primary particle size rises as the roasting temperature increases from 600 to 750 °C. The Li₂FeSiO₄/C sample synthesized at 650 °C has good electrochemical performances with an initial discharge capacity of 144.9 mAh g⁻¹ and the discharge capacity remains 136.5 mAh g⁻¹ after 10 cycles. The performance of Li₂FeSiO₄/C cathode is further improved by modification of Ni substitution. The Li₂Fe_0.9Ni_0.1SiO₄/C composite cathode has an initial discharge capacity of 160.1 mAh g⁻¹, and the discharge capacity remains 153.9 mAh g⁻¹ after 10 cycles. The diffusion coefficient of lithium in Li₂FeSiO₄/C is 1.38 × 10⁻¹² cm² s⁻¹ while that in Li₂Fe_0.9Ni_0.1SiO₄/C reaches 3.34 × 10⁻¹² cm² s⁻¹.     

Characterization of atmospheric plasma-sprayed La0.8Sr0.2Ga0.8Mg0.2O3 electrolyte

La_0.8Sr_0.2Ga_0.8Mg_0.2O₃ (LSGM) deposit in free standing planar shape was prepared by atmospheric plasma spraying (APS) to examine the coating microstructure and electrical conductivity to aim at applying APS LSGM to solid oxide fuel cells (SOFCs). The electrical conductivity of the plasma-sprayed LSGM coating was investigated. The coating microstructure was characterized by X-ray diffraction and scanning electron microscopy. The result showed that a fraction amorphous phase was present in the as-sprayed LSGM deposit, which starts to recrystallize at the temperature of 785 °C. The electrical conductivities of the LSGM with recrystallization treatment are 0.04 and 0.09 S cm⁻¹ at 1000 °C at the directions perpendicular and parallel to the coating surfaces, respectively. The electrical conductivity at perpendicular direction is about one-tenth that of sintered bulk at 1000 °C. This result is due to the lamellar structure feature with the limited interface bonding which dominates the electrical conductivity of APS coatings. The activation energy for ion conduction within APS-deposited LSGM deposit depends on temperature range. The change of activation energy indicates that the ion transportation dominant changes with temperature.     

Electrochemical performance of In2O3 thin film electrode in lithium cell

Indium oxide (In₂O₃) coating on Pt, as an electrode of thin film lithium battery was carried out by using cathodic electrochemical synthesis in In₂(SO₄)₃ aqueous solution and subsequently annealing at 400 °C. The coated specimens were characterized by X-ray photoelectron spectroscopy (XPS) for chemical bonding, X-ray diffraction (XRD) for crystal structure, scanning electron microscopy (SEM) for surface morphology, cyclic voltammetry (CV) for electrochemical properties, and charging/discharging test for capacity variations. The In₂O₃ coating film composed of nano-sized particles about 40 nm revealing porous structure was used as the anode of a lithium battery. During discharging, six lithium ions were firstly reacted with In₂O₃ to form Li₂O and In, and finally the Li_4.33In phase was formed between 0.7 and 0.2 V, revealing the finer particles size about 15 nm. The reverse reaction was a removal of Li⁺ from Li_4.33In phase at different oxidative potentials, and the rates of which were controlled by the thermodynamics state initially and diffusion rate finally. Therefore, the total capacity was increased with decreasing current density. However, the cell delivering a stable and reversible capacity of 195 mAh g⁻¹ between 1.2 and 0.2 V at 50 μA cm⁻² may provide a choice of negative electrode applied in thin film lithium batteries.     

Al-doped Li7La3Zr2O12 synthesized by a polymerized complex method

Li₇La₃Zr₂O₁₂ electrolytes doped with different amounts of Al (0, 0.2, 0.7, 1.2, and 2.5 wt.%) were prepared by a polymerized complex (Pechini) method. The influence of aluminum on the structure and conductivity of Li₇La₃Zr₂O₁₂ were investigated by X-ray diffraction (XRD), impedance spectroscopy, scanning electron microscopy (SEM), and thermal dilatometry. It was found that even a small amount of Al (e.g. 0.2 wt.%) added to Li₇La₃Zr₂O₁₂ can greatly accelerate densification during the sintering process. SEM micrographs showed the existence of a liquid phase introduced by Al additions which led to the enhanced sintering rate. The addition of Al also stabilized the higher conductivity cubic form of Li₇La₃Zr₂O₁₂ rather than the less conductive tetragonal form. The combination of these two beneficial effects of Al enabled greatly reduced sintering times for preparation of highly conductive Li₇La₃Zr₂O₁₂ electrolyte. With optimal additions of Al (e.g. 1.2 wt.%), Li₇La₃Zr₂O₁₂ electrolyte sintered at 1200 °C for only 6 h showed an ionic conductivity of 2.0 × 10⁻⁴ S cm⁻¹ at room temperature.     

In situ high temperature neutron powder diffraction study of La2Ni0.6Cu0.4O4+δ in air: Correlation with the electrical behaviour

The knowledge of the thermal evolution of the crystal structure of a cathode material across the usual working conditions in solid oxide fuel cells is essential to understand not only its transport properties but also its chemical and mechanical stability in the working environment. In this regard, high-resolution neutron powder diffraction (NPD) measurements have been performed in air from 25 to 900 °C on O₂-treated (350 °C/200 bar) La₂Ni_0.6Cu_0.4O_4+δ. The crystal structure was Rietveld-refined in the tetragonal F4/mmm space group along all the temperature range. The structural data have been correlated with the transport properties of this layered perovskite. The electrical conductivity of O₂-treated La₂Ni_0.6Cu_0.4O_4+δ exhibits a metal (high T)-to-semiconductor (low T) transition as a function of temperature, displaying a maximum value of 110 S cm⁻¹ at around 450 °C. The largest conductivity corresponds, microscopically, to the shortest axial Ni–O2 distance (2.29(1) Å), revealing a major anisotropic component for the electronic transport. We have also performed a durability test at 750 °C for 560 h obtaining a very stable value for the electrical conductivity of 87 S cm⁻¹. The thermal expansion coefficient was 12.8 × 10⁻⁶ K⁻¹ very close to that of the usual SOFC electrolytes. These results exhibit La₂Ni_0.6Cu_0.4O_4+δ as a possible alternative cathode for IT-SOFC.