Atmospheric plasma spraying to fabricate metal-supported solid oxide fuel cells with open-channel porous metal support

Metal-supported solid oxide fuel cells (MS-SOFCs) have been fabricated by applying phase-inversion tape-casting and atmospheric plasma spraying (APS). The effect of the binder amount of the phase-inversion slurries on the microstructure development of the 430L stainless steel metal support was investigated. The pore structures, the viscosity of the slurry, porosity and permeability of the as-prepared metal supports are significantly influenced by the amount of the binder. NiO–scandia-stabilized zirconia (ScSZ) anode, ScSZ electrolyte and La_0.6Sr_0.4Co_0.2Fe_0.8O_3?δ (LSCF) cathode layers were consecutively deposited on the metal support with an ideal microstructure by APS process. The effect of plasma power of the APS on the microstructure of the electrolyte and cathode was investigated. A dense electrolyte layer and a porous cathode layer were successfully obtained at 40 and 6 kW of the APS plasma power, respectively. MS-SOFCs, with a cell configuration of 430L/Ni-ScSZ/ScSZ/LSCF, achieved a maximum cell power density of 1079 mW cm^?2 at 700°C using humidified H₂ as fuel and ambient air as oxidant. The corresponding ohmic resistance and total resistance of MS-SOFCs was 0.14 and 0.32 Ω cm², respectively. This work demonstrates the feasibility of fabricating high-performance MS-SOFCs with economical and scalable techniques.