Deposition of solid oxide fuel cell electrodes by solution precursor plasma spray

Porous La1-xSrxMnO3 (LSM) perovskite cathodes and Yttria Stabilized Zirconia (YSZ)-Nickel (Ni) anodes were successfully deposited by direct current arc solution precursor plasma spray (DC-SPPS), in which a solution precursor of the product material was injected into DC plasma jet.;The deposition mechanisms, such as the changes in the solution precursor with the increase of temperature and the evolution of the droplet as it moved along the plasma jet, as well as the impact of the synthesized particles onto the substrate, were investigated. The effects of processing parameters on the microstructure and phase composition of the fabricated LSM cathode and Ni-YSZ anode were examined systematically using TGA/TDA, XRD and SEM. Coating deposition efficiencies and porosities as a function of processing parameters were analyzed by statistical experimental design techniques, based on which the deposition processes were optimized. In addition, the hardness and electrical resistance of the fabricated coatings were measured.;From the theoretical and experimental analyses conducted, a comprehensive description of the DC-SPPS process was developed. The precursor solution droplets undergo breakup; solvent evaporation and precursor salt precipitation and crystallization; precursor salt melting and decomposition; nucleation and growth of particles of the product phase; agglomeration, sintering, and perhaps melting of these particles; and impact onto the substrate. The breakup of droplets can only occur in the short period of time after the droplets are injected into the plasma jet. Agglomeration of droplets or particles may occur at any point along the plasma plume. This work has clearly established: (a) the critical importance of droplet breakup and the agglomeration of precursors or synthesized particles in-flight in the plasma jet in determining the structure of the deposited coating, and (b) the basis of the low deposition efficiencies obtained in DC-SPPS.;The microstructure and phase composition of the deposited coatings were dependent on several processing parameters. By changing process parameters, phase pure LSM perovskite cathode coatings with 20%--40% porosity were produced. The LSM coatings were mainly built up by porous agglomerates of small spherical particles. Anode coatings predominately consist of porous agglomerates of small spherical YSZ particles (0.5 mum) homogenously distributed in a continuous Ni matrix. The anode coatings have 29--51% porosity.