Thermal Induction Plasma Processes for the Synthesis of SOFC Materials

This work demonstrates the potential of two recently developed plasma spray methods to deposit Sr‐doped La‐(Mn,Fe,Co) perovskite (LSM, LSF, LSCF) cathodes, and yttria‐doped zirconia (YSZ) electrolytes as components of solid oxide fuel cells (SOFC). These methods are Thermal Plasma Chemical Vapour Deposition (TPCVD) and Suspension Plasma Spraying (SPS). The microstructure obtained is determined by the method applied. TPCVD results in either globular or columnar coatings which were deposited with growth rates up to 30 μm/min. SPS with a deposition rate in excess of 100 μm/min yields coatings of layered microstructure. The homogeneity of the dopant distribution and the phase purity of YSZ is excellent. Process modifications will be necessary, however, to improve the properties in the case of perovskite coatings.