Manufacturing Solid Oxide Fuel Cells with an Axial-injection Plasma SpraySystem

摘要

Atmospheric plasma spraying has emerged as a cost-effectivealternative to traditional sintering processes for solid oxidefuel cell (SOFC) manufacturing. However, the use of plasmaspraying for SOFCs presents unique challenges, mainly due tothe high porosity required for the electrodes and fully densecoatings required for the electrolytes. By using optimizedspray conditions combined with appropriate feedstocks, SOFCelectrolytes and electrodes with required composition andmicrostructure could be deposited with an axial plasma spraysystem. In this paper, the challenges for manufacturing SOFCanodes, electrolytes, and cathodes are addressed. The effectsof plasma parameters and different feedstocks on coatingmicrostructure are discussed, and examples of optimizedcoating microstructures are given.