Development of solid oxide fuel cells (SOFCs) by tape-casting and single-step co-firing of monolithic laminates

We developed a cost-effective method to manufacture high performance-monolithic solid oxide fuel cells using nano-composite electrodes, tape-casting and single-step co-firing. NiO/YSZ-YSZ nano-composite powder comprising nano-sized NiO and YSZ adhered to core YSZ powder was prepared for anode support. LSM/GDC nano-composite cathode fired at 1400 C had a porosity of over 20%, which was much higher than that of conventional LSM-GDC. Furthermore, the area specific resistance of the LSM/GDC cathode was 0.15 Ω cm ², which was much lower than that of the LSM-GDC and LSM-YSZ mechanically mixed cathodes. Various types of monolithic SOFC unit cells were prepared; one consisting of a NiO-YSZ anode, NiO/YSZ-YSZ anode functional layer, and LSM-GDC cathode had a current density of 0.37 A/cm² at 0.7 V at 800 C. Optimized monolithic SOFC consisting of NiO/YSZ-YSZ anode and YSZ electrolyte and LSM/GDC cathode had a greatly improved current density of 0.84 A/cm².