Flame Spray Synthesis of Nanoscale La0.6Sr0.4Co0.2Fe0.8O3–δ and Ba0.5Sr0.5Co0.8Fe0.2O3–δ as Cathode Materials for Intermediate Temperature Solid Oxide Fuel Cells

Electrochemical performance and degradation was analysed by conductivity measurements as well as thermogravimetric analysis (TGA) under different atmospheres. CO₂ was identified as a critical parameter in terms of carbonate formation from Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3–δ and causes a strong increase in the material resistivity, whereas La_0.6Sr_0.4Co_0.2Fe_0.8O_3–δ is unaffected. The oxygen exchange kinetic of both compositions is affected by CO₂ containing atmospheres.     

Optimisation and Evaluation of La0.6Sr0.4CoO3 – δ Cathode for Intermediate Temperature Solid Oxide Fuel Cells

In this work, La_0.6Sr_0.4CoO_{3 – δ}/Ce_{1 – x}Gd_xO_{2 – δ} (LSC/GDC) composite cathodes are investigated for SOFC application at intermediate temperatures, especially below 700 °C. The symmetrical cells are prepared by spraying LSC/GDC composite cathodes on a GDC tape, and the lowest polarisation resistance (R_p) of 0.11 Ω cm² at 700 °C is obtained for the cathode containing 30 wt.‐% GDC. For the application on YSZ electrolyte, symmetrical LSC cathodes are fabricated on a YSZ tape coated on a GDC interlayer. The impact of the sintering temperature on the microstructure and electrochemical properties is investigated. The optimum temperature is determined to be 950 °C; the corresponding R_p of 0.24 Ω cm² at 600 °C and 0.06 Ω cm² at 700 °C are achieved, respectively. An YSZ‐based anode‐supported solid oxide fuel cell is fabricated by employing LSC/GDC composite cathode sintered at 950 °C. The cell with an active electrode area of 4 × 4 cm² exhibits the maximum power density of 0.42 W cm^–2 at 650 °C and 0.54 W cm^–2 at 700 °C. More than 300 h operating at 650 °C is carried out for an estimate of performance and degradation of a single cell. Despite a decline at the beginning, the stable performance during the later term suggests a potential application.     

Electrochemical Performance of Cobalt‐free Nd0.5Ba0.5Fe1–xNixO3–δ Cathode Materials for Intermediate Temperature Solid Oxide Fuel Cells

A new series of cobalt‐free perovskite‐type oxides, Nd_0.5Ba_0.5Fe_1–xNi_xO_3–δ (0 ≤ x ≤ 0.15), have been prepared by a citric acid‐nitrate process and investigated as cathode materials for proton conducting intermediate temperature solid oxide fuel cells (IT‐SOFCs). The conductivity of the oxides was measured at 300–800 °C in air. It is discovered that partial substitution of Ni for Fe‐sites in Nd_0.5Ba_0.5Fe_1–xNi_xO_3–δ obviously enhances the conductivity of the oxides. Among the series of oxides, the Nd_0.5Ba_0.5Fe_0.9Ni_0.1O_3–δ (NBFNi10) exhibits the highest conductivity of 140 S cm⁻¹ in air at 550 °C. A single H₂/air fuel cell with proton‐conducting BaZr_0.1Ce_0.7Y_0.2O_3–δ (BZCY) electrolyte membrane (ca. 40 μm thickness) and NBFNi10‐BZCY composite cathode and NiO‐BZCY composite anode was fabricated and tested at 600–700 °C. The peak power density and the interfacial polarization resistance (R_p) of the cell are 490 mW cm⁻² and 0.15 Ω cm² at 700 °C, respectively. The experimental results indicate that NBFNi10 is a promising cathode material for the proton‐conducting IT‐SOFCs.     

固体氧化物燃料电池金属连接极涂层材料YCo0.6Mn0.4O3的性能

通过丝网印刷法在SS410合金上涂覆YCo0.6Mn0.4O3抗氧化涂层材料,采用氧化增重法、SEM-EDX、四探针法分别对SS410合金及其涂覆抗氧化涂层后的高温氧化速率、微观形貌和面积比电阻进行了表征. 结果表明,通过丝网印刷法在合金表面涂覆连续致密的陶瓷涂层材料,YCo0.6Mn0.4O3涂层在循环氧化过程中与基底结合牢固,没有出现剥离脱落. 涂覆YCo0.6Mn0.4O3涂层后,在800℃下SS410合金的氧化速率降低1个数量级,在800℃氧化150 h合金的面积比电阻由未涂层的72 mW×cm2降到了16 mW×cm2,大幅度地提高了合金的高温抗氧化性能及电导性能.     

Characterization of La0.6Sr0.4Co0.2Fe0.8O3–δ + La2NiO4+δ Composite Cathode Materials for Solid Oxide Fuel Cells

The structure, electrical conduction, thermal expansion and electrochemical properties of the La_0.6Sr_0.4Co_0.2Fe_0.8O_3–δ + La₂NiO_4+δ (LSCF‐LNO) composite cathodes were investigated with regard to the volume fraction of the LNO composition. No chemical reaction product between the two constituent phases was found for the composite cathodes sintered at 1,400 °C for 10 h within the sensitivity of the XRD. Compared to the performance of the LSCF cathode, the LNO composition in the composite cathode plays a role in deteriorating both electrical conductivity and electrochemical properties, however, improving the thermal expansion properties. The trade‐off between electrical conducting and thermal expansion classifies the composite cathode containing 30 volume percent (vol.%) LNO as the optimum composition. For characterizing cathode performance in a single cell, a slurry spin coating technique was employed to prepare a porous cathode layer as well as a YSZ/Ce_0.8Sm_0.2O_3–δ (SDC) electrolyte. The optimum conditions for fabricating the YSZ/SDC electrolyte were investigated. The resulting single cell with 70 vol.% LSCF‐30 vol.%LNO (LSCF‐LNO30) cathode shows a power density of 497 mW cm^–2 at 800 °C, which is lower than that of the cell with a LSCF cathode, but still within the limits acceptable for practical applications.     

Electrochemical Performance of Nd1.95NiO4+δ Cathode supported Microtubular Solid Oxide Fuel Cells

Nd_1.95NiO_4+δ (NNO) cathode supported microtubular cells were fabricated and characterized. This material presents superior oxygen transport properties in comparison with other commonly used cathode materials. The supporting tubes were fabricated by cold isostatic pressing (CIP) using NNO powders and corn starch as pore former. The electrolyte (GDC, gadolinia doped ceria based) was deposited by wet powder spraying (WPS) on top of pre‐sintered tubes and then co‐sintered. Finally, a NiO/GDC suspension was dip‐coated and sintered as the anode. Optimization of the cell fabrication process is shown. Power densities at 750 °C of ∼40 mWcm⁻² at 0.5V were achieved. These results are the first electrochemical measurements reported using NNO cathode‐supported microtubular cells. Further developments of the fabrication process are needed for this type of cells in order to compete with the standard microtubular solid oxide fuel cells (SOFC).     

Studies on Composite Cathode with Nanostructured Ce0.9Sm0.1O1.95 for Intermediate Temperature Solid Oxide Fuel Cells

A kind of nanostructured Ce_0.9Sm_0.1O_1.95 is prepared by a hydrothermal method. It exhibits large Brunauer‐Emmett‐Teller area (>120 m² g^–1), open mesoporous structure and nanocrystalline sheets. This material shows high activity for oxygen reduction. An area specific resistance below 0.6 Ω cm² at 600 °C is achieved when it is mixed with Ag paste as a composite cathode in a symmetric cell. This is attributed to its large triple phase boundary area and good ionic conducting property. The influences of microstructure, doping, loading effects of silver nanoparticles and the temperature dependence on oxygen reduction kinetics are investigated by the impedance spectroscopy. Although some further optimisations are still required, this special Ce_0.9Sm_0.1O_1.95 material reported here exhibits promising features of applications in the composite electrodes for intermediate temperature solid oxide fuel cells (IT‐SOFCs).     

Electrochemical Performance of PrBaCo2O5+δ and Sm0.5Sr0.5CoO3−δ Infiltrated Ce0.9Gd0.1O1.95 Cathodes

Cathodes with PrBaCo₂O_5+δ (PBC) and Sm_0.5Sr_0.5CoO_3−δ (SSC) infiltrated on Ce_0.9Gd_0.1O_1.95 (CGO) backbones are prepared using metal nitrates as precursors and ethanol as wetting agent. Electrochemical impedance spectra (EIS) are measured from cathode/CGO/cathode symmetrical cells in 400–650 °C under humidified air. The results indicate that interfacial area specific resistance (ASR) value decreases and then increases with infiltrate loading and minimum values occur at 50 wt.% loading (relative to sum of infiltrate and backbone) for both PBC and SSC infiltrates. ASR values of PBC infiltrated cathodes are lower than that of corresponding SSC infiltrated cathodes in general, and in particular ASR values as low as 1.36 × 10⁻² and 2.27 × 10⁻² Ω cm² are obtained at 650 °C in air for 50 wt.% PBC and 50 wt.% SSC infiltrated cathodes, respectively. Conductivity values of CGO electrolyte increase with infiltrate loading and agree with the reported values when the loading reaches 50 wt.%.     

A Performance Study of Solid Oxide Fuel Cells With BaZr0.1Ce0.7Y0.2O3–δ Electrolyte Developed by Spray‐Modified Pressing Method

Fuel cells with BaZr_0.1Ce_0.7Y_0.2O_3–δ (BZCY) proton‐conducting electrolyte is fabricated using spray‐modified pressing method. In the present study the spray‐modified pressing technology is developed to prepare thin electrolyte layers on porous Ni‐BZCY anode supports. SEM data show the BZCY electrolyte film is uniform and dense, well‐bonded with the anode substrate. An anode‐supported fuel cell with BZCY electrolyte and Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3–δ (BSCF) cathode is characterized from 600 to 700 °C using hydrogen as fuel and ambient air as oxidant. Maximum power density of 536 mW cm^–2 along with a 1.01 V OCV at 700 °C is obtained. Impedance spectra show that Ohmic resistances contribute minor parts to the total ones, for instance, only ~23% when operating at 600 °C. The results demonstrate that spray‐modified pressing technology offers a simple and effective way to fabricate quality electrolyte film suitable to operate in intermediate temperature.     

Evaluation of Using LaNi0.6Fe0.4O3–δ Contact Layer Between La0.6Sr0.4FeO3 Cathode and Crofer22APU Interconnect for Solid Oxide Fuel Cells

Interconnect‐cathode interfacial adhesion is important for the durability of solid oxide fuel cell (SOFC). Thus, the use of a conductive contact layer between interconnect and cathode could reduce the cell area specific resistance (ASR). The use of La_0.6Sr_0.4FeO₃ (LSF) cathode, LaNi_0.6Fe_0.4O_3–δ (LNF) contact layer and Crofer22APU interconnect was proposed as an alternative cathode side. LNF‐LSF powder mixtures were heated at 800 °C for 1,000 h and at 1,050 °C for 2 h and analyzed by X‐Ray power diffraction (XRD). The results indicated a low reactivity between the materials. The degradation occurring between the components of the half‐cell (LSF/LNF/Crofer22APU) was studied. XRD results indicated the formation of secondary phases, mainly: SrCrO₄, A(B, Cr)O₃ (A = La, Sr; B = Ni, Fe) and SrFe₁₂O₁₉. Scanning electron microscopy with energy dispersive X‐Ray spectroscopy (SEM‐EDX) and the X‐Ray photoelectron spectroscopy (XPS) analyzes confirmed the interaction between LSF/LNF and the metallic interconnect due to the Cr vaporization/migration. An increment of the resistance of ∼0.007 Ω cm² in 1,000 h is observed for (LSF/LNF/Crofer22APU) sample. However, the ASR values of the cell without contact coating, (LSF/Crofer22APU), were higher (0.31(1) Ω cm²) than those of the system with LNF coated interconnect (0.054(7) Ω cm²), which makes the proposed materials combination interesting for SOFC.     

Influence of Microwave‐Assisted Pechini Method on La0.80Sr0.20Ga0.83Mg0.17O3–δ Ionic Conductivity

With the aim of investigating the microwave influence on the electrolyte material properties, La_0.80Sr_0.20Ga_0.83Mg_0.17O_2.815 was prepared by both a conventional and a microwave‐assisted sol–gel Pechini method. With respect to the conventional Pechini method (hereafter SGP), the microwave assisted process (hereafter MWA‐SGP) guaranteed a faster procedure, reducing the time needed to remove the excess solvents to complete the polyesterification reaction from some days to a few hours. In fact, when a MWA‐SGP method was used, powders having higher phase purity were obtained. The sintering process at 1,450 °C of the powders prepared by both methods yielded pellets with similar density values (≥92% of theoretical). Nevertheless, only by microwave‐assisted process single‐phase products were obtained and no secondary phases such as tetragonal LaSrGaO₄ and LaSrGa₃O₇ were detected. These by‐products have been demonstrated to be detrimental for conductivity. Indeed, pellets obtained by MWA‐SGP method showed oxygen ionic conductivity values higher (about 30–40%) than those checked for SGP samples, thus demonstrating the important role of the microwave process on reducing time and costs and on improving the electrolyte properties.     

Moisture Effect on La0.8Sr0.2MnO3 and La0.6Sr0.4Co0.2Fe0.8O3 Cathode Behaviors in Solid Oxide Fuel Cells

Moisture effect on cathode behaviors is a major issue for solid oxide fuel cells servicing under severe high temperature environments. This work studies the effect of dry air and moist air on La_0.8Sr_0.2MnO₃ (LSM821) and La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF6428) cathodes at 800 °C by investigating the interfacial reaction and degradation through an AISI 441 interconnect/LSM821 (LSCF6428) electrode/yttria‐stabilized zirconia (YSZ) electrolyte tri‐layer structure. Under the same processing condition, the grain size of the LSCF6428 cathode is smaller than that of the LSM821 cathode. Ohmic resistance and polarization resistance of the cathodes are analyzed by deconvoluting the electrochemical impedance spectroscopy (EIS) results. The LSCF6428 cathode has much smaller resistance than the LSM821 cathode. Moisture produces a larger effect on the ohmic resistance and polarization resistance of the LSM821 cathode than on those of the LSCF6428 cathode. More chromium diffuses from the interconnect to the cathode for both LSM821 and LSCF6428 electrodes thermally treated in moist air. Based on the structure, elemental distribution, and EIS analysis, the interaction mechanisms between the electrodes and the AISI 441 alloy interconnect are proposed.     

In Situ Measurements on Solid Oxide Fuel Cell Cathodes – Simultaneous X‐Ray Absorption and AC Impedance Spectroscopy on Symmetrical Cells

A solid oxide fuel cell in operando is a complex multiphasic entity under electrical polarization and operating at high temperatures. In this work, we reproduce these conditions while studying transition metal redox chemistry in situ at the cathode. This was achieved by building a furnace that allowed for X‐ray absorption near‐edge structure and AC impedance spectroscopy data to be obtained simultaneously on symmetrical cells while at operating temperatures. The cell electrodes consisted of phases from the Ruddlesden–Popper family; La₂NiO_4+δ, La₄Ni₃O_10–δ, and composites thereof. The redox chemistry of nickel in these cathodes was probed in situ through investigation of changes in the position of the X‐ray absorption K‐edge. An oxidation state reduction (Ni³⁺ to Ni²⁺) was observed on heating the cells; this was correlated to changing concentrations of ionic charge carriers in the electrode. Polarizing the cells resulted in dramatic changes to their electrical performance but not to the bulk redox chemistry of the electrode. The implications of this with respect to explaining the polarization behavior are discussed.     

Operational Inhomogeneities in La0.9Sr0.1Ga0.8Mg0.2O3–δ Electrolytes and La0.8Sr0.2Cr0.82Ru0.18O3–δ–Ce0.9Gd0.1O2–δ Composite Anodes for Solid Oxide Fuel Cells

The electrolyte/anode interface in solid oxide fuel cells with La_0.9Sr_0.1Ga_0.8Mg_0.2O_3–δ electrolytes and composite anodes containing La_0.8Sr_0.2Cr_0.82Ru_0.18O_3–δ and Ce_0.9Gd_0.1O_2–δ (GDC) was studied using transmission electron microscope Z‐contrast imaging and energy dispersive X‐ray spectroscopy. The anode/electrolyte interface of an operated cell had numerous defective regions in the electrolyte, immediately adjacent to anode GDC particles. These areas had a different chemical composition than other electrolyte regions and were crystallographically inhomogeneous. These regions were not observed in a cell reduced in hydrogen that was not operated, suggesting that they were the result of combined electrical and chemical potential gradients present during cell operation. Ru nanoparticles were observed on the chromite surfaces of the operated.     

Influence of Barium Incorporation on the Electrochemical Performance of Ln0.58Sr0.4Fe0.8Co0.2O3–δ (Ln=La,Pr, Sm) Perovskites for Oxygen Activation at Intermediate Temperatures

Highly active perovskite‐based electrodes were obtained through partial substitution of lanthanides (La, Pr and Sm) by barium in the Ln_0.58Sr_0.4Fe_0.8Co_0.2O₃ system. These compositions were obtained as single phase crystalline compounds through a sol–gel synthetic route and tested by electrochemical impedance spectroscopy (EIS) as symmetrical cells on GDC‐electrolyte samples in the temperature range 450–650 °C. Cooperative effects arose through the incorporation of a large divalent active cation (Ba⁺²) in the perovskite lattice of lanthanide‐based strontium ferrites‐cobaltites. Reduction in the electrode polarisation resistance with respect to non‐substituted compositions is obtained irrespective of the amount of barium substitution and lanthanide nature. Barium addition also reduces the activation energy of these compositions, indicating changes in the oxygen activation processes. The specific effect of the barium incorporation on the electrode performance was dependent on the nature of the partially substituted lanthanide. Lanthanum–barium‐based compositions exhibited the lowest electrode polarisation resistance when the amount of the replaced barium was increased up to 50% molar. On the other hand, for praseodymium‐ or samarium–barium‐based compositions, the minimum in electrode polarisation resistance was achieved at barium substitutions close to 25% molar. The study of the effect of oxygen partial pressure on EIS data allowed in improving the understanding of the processes governing the electrode operation.     

Fabrication of BaZr0.1Ce0.7Y0.2O3 – δ ‐Based Proton‐Conducting Solid Oxide Fuel Cells Co‐Fired at 1,150 °C

Dense proton‐conducting BaZr_0.1Ce_0.7Y_0.2O_{3 – δ} (BZCY) electrolyte membranes were successfully fabricated on NiO–BZCY anode substrates at a low temperature of 1,150 °C via a combined co‐press and co‐firing process. To fabricate full cells, the LaSr₃Co_1.5Fe_1.5O_{10 – δ}–BZCY composite cathode layer was fixed to the electrolyte membrane by two means of one‐step co‐firing and two‐step co‐firing, respectively. The SEM results revealed that the cathode layer bonded more closely to the electrolyte membrane via the one‐step co‐firing process. Correspondingly, determined from the electrochemical impedance spectroscopy measured under open current conditions, the electrode polarisation and Ohmic resistances of the one‐step co‐fired cell were dramatically lower than the other one for its excellent interface adhesion. With humidified hydrogen (2% H₂O) as the fuel and static air as the oxidant, the maximum power density of the one‐step co‐fired single cell achieved 328 mW cm^–2 at 700 °C, showing a much better performance than that of the two‐step co‐fired single cell, which was 264 mW cm^–2 at 700 °C.     

Design of BaZr0.8Y0.2O3–δ Protonic Conductor to Improve the Electrochemical Performance in Intermediate Temperature Solid Oxide Fuel Cells (IT‐SOFCs)

BaZr_0.8Y_0.2O_3–δ, (BZY), a protonic conductor candidate as an electrolyte for intermediate temperature (500–700 °C) solid oxide fuel cells (IT‐SOFCs), was prepared using a sol–gel technique to control stoichiometry and microstructural properties. Several synthetic parameters were investigated: the metal cation precursors were dissolved in two solvents (water and ethylene glycol), and different molar ratios of citric acid with respect to the total metal content were used. A single phase was obtained at a temperature as low as 1,100 °C. The powders were sintered between 1,450 and 1,600 °C. The phase composition of the resulting specimens was investigated using X‐ray diffraction (XRD) analysis. Microstructural characterisation was performed using field emission scanning electron microscopy (FE‐SEM). Chemical stability of the BZY oxide was evaluated upon exposure to CO₂ for 3 h at 900 °C, and BZY showed no degradation in the testing conditions. Fuel cell polarisation curves on symmetric Pt/BZY/Pt cells of different thicknesses were measured at 500–700 °C. Improvements in the electrochemical performance were obtained using alternative materials for electrodes, such as NiO‐BZY cermet and LSCF (La_0.8Sr_0.2Co_0.8Fe_0.2O₃), and reducing the thickness of the BZY electrolyte, reaching a maximum value of power density of 7.0 mW cm^–2 at 700 °C.     

Integration of Spin‐Coated Nanoparticulate‐Based La0.6Sr0.4CoO3–δ Cathodes into Micro‐Solid Oxide Fuel Cell Membranes

Thin cathodes for micro‐solid oxide fuel cells (micro‐SOFCs) are fabricated by spin‐coating a suspension of La_0.6Sr_0.4CoO_3–δ (LSC) nanoparticulates obtained by salt‐assisted spray pyrolysis. The resulting 250 nm thin LSC layers exhibit a three‐dimensional porous microstructure with a grain size of around 45 nm and can be integrated onto free‐standing 3 mol.% yttria‐stabilized‐zirconia (3YSZ) electrolyte membranes with high survival rates. Weakly buckled micro‐SOFC membranes enable a homogeneous distribution of the LSC dispersion on the electrolyte, whereas the steep slopes of strongly buckled membranes do not allow for a perfect LSC coverage. A micro‐SOFC membrane consisting of an LSC cathode on a weakly buckled 3YSZ electrolyte and a sputtered Pt anode has an open‐circuit voltage of 1.05 V and delivers a maximum power density of 12 mW cm^–2 at 500 °C.     

A Layered Perovskite EuBaCo2O5+δ for Intermediate‐Temperature Solid Oxide Fuel Cell Cathode

A layered perovskite EuBaCo₂O_5+δ (EBCO) has been prepared by a solid‐state reaction, and evaluated as potential cathode for intermediate‐temperature solid oxide fuel cells. Structural characterizations are determined at room temperature using powder X‐ray diffraction and transmission electron microscopy technique. The good fits to the XRD data by Rietveld refinement method are obtained in the orthorhombic space group (Pmmm). The lower average thermal expansion coefficient, 14.9 × 10^–6 °C^–1 between 100 and 800 °C, indicates its better thermal expansion compatibility with conventional electrolytes, compared with the other cobalt‐containing cathode materials. The high electrical conductivity and large oxygen nonstoichiometry at intermediate temperatures suggest the effective charge transfer reactions including electron conduction and oxide‐ion motion in cathode. As a result, a highly electrochemical activity towards the oxygen reduction reaction is achieved between 600 and 700 °C, as evidenced by low area‐specific resistances, e.g. 0.14–0.5 Ω cm². In addition, cathodic overpotential and oxygen reduction kinetics of the EBCO cathode have also been studied.