The rapid one-step fabrication of bilayer anode for protonic ceramic fuel cells by phase inversion tape casting

The bilayer anode fabricated by phase inversion tape casting has an excellent microstructure for protonic ceramic fuel cell compared with the dry pressing method. The large diameter and straight hole structure facilitates the fuel gas transportation thus eliminates the concentration polarization loss. But a dense skin layer (70 μm) results in a power density of only 150 mWcm⁻² at 600 ℃. The anode added with 10 wt% corn starch could eliminate the skin layer, but cause a mismatch between electrolyte suspension and anode. To resolve the mismatch between electrolyte and anode, an anode functional layer (AFL) is employed with different content of corn starch (10−40 wt%). Finally, the single cell with optimized bilayer anode has a maximum power density of 574 mWcm⁻² at 650 ℃. This work provides an easy and rapid method for the preparation of planar protonic ceramic fuel cell with satisfactory performance at intermediate temperature range.