Investigation of the feasibility of manufacturing solid oxide fuel cell graded electrolytes by suspension plasma spraying

Solid oxide fuel cell compositionally graded electrolytes could offer the advantage of improving electrical performance and efficiency compared to single-layered or bi-layered yttria stabilized zirconia and samaria doped ceria electrolytes and improving mechanical performance by reducing thermal expansion mismatch stresses compared to bi-layered electrolytes with sharp interfaces. Manufacturing of these graded structures is difficult if implementing conventional wet ceramic techniques. Suspension plasma spraying is an emerging technology that has the potential to rapidly produce thin, dense ceramic layers with no requirement for post deposition heat treatments. However, SPS requires a careful examination of the stability of the feedstock suspensions in order to produce high quality coatings. Optimum suspension formulations with excellent particle dispersion were designed based on rheological and electrostatic stability measurements. These optimized suspensions were used as feedstocks for the fabrication of suspension plasma sprayed compositionally graded YSZ/SDC layers. The feasibility of fabricating graded electrolyte structures was thus demonstrated.