To cut down the energy consumption and processing period, Ni-YSZ anode-supported thin YSZ electrolyte SOFCs have been fabricated by an improved dip-coating technique, in which the electrolyte layer was dip-coated on green anode substrates instead of prefired ones, followed by co-firing. The film formation mechanisms of dip-coating were analyzed with liquid entrainment and capillary effect assumptions. According to the mechanisms, a typical YSZ electrolyte slurry formula of conventional dip-coating technique was modified for the improved technique by increasing the binder content and the solid loading. With the improved dip-coating technique, along with an optimized electrolyte slurry formula, a SOFC with dense electrolyte, revealing a maximum power density of 460mW/cm(2) at 800 degrees C, was obtained. Factors affecting the coating layers were also investigated by SEM and AC impedance analyses.
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