Nanocomposite Powder Synthesis and Cathode Coating Deposition for Intermediate Temperature Solid Oxide Fuel Cell

In this work, nanocomposite cathode powder and nano/micro-structured composite cathodes for intermediate temperature solid oxide fuel cells (IT-SOFCs) have been produced using induction plasma spray. Both the suspension plasma spray (SPS) and solution plasma spray (SolPS) method were used. The composite cathode is a mixture of electronic and ionic conductor (ceramic oxide) with enough porosity for the oxygen gas to pass and have the expansion coefficient compatibility with the electrolyte as well.;For the purpose of SOFC commercialization, there is a trend to develop SOFCs working at a medium temperature range (600-800°C). This not only expands the choice of materials and stack geometries that can be used but also reduces system cost and, in principle, decreases the degradation rate of the stack and system components. In order to reduce the polarization resistance of the cathode at this temperature range, two approaches are proposed for cathode fabrication: a) using the materials both with high ionic and electronic conductivities, such as adding a second phase into the original cathode material; b) producing the cathode with homogeneous nano/micro-structure.;SolPS method was used to synthesize nanopowders with mixed conductivity. The solution precursor was prepared with the mixed stoichiometric metal nitrates, glycine and distilled water. The crystallinity and morphological features of the nanopowders were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and energy dispersive spectroscopy (EDS). Afterwards, the suspensions, made with ethanol and previously synthesized composite nanopowders were used to deposit cathode coatings by SPS process. The parameters of the SPS processes are optimized to obtain cauliflower microstructure with maximized homogeneity and appropriate open porosity. Cathodes produced by a SPS process were compared to the ones produced using a SolPS process. The coatings were characterized by the high resolution SEM. Symmetrical SPS cathode-electrolyte-cathode was also fabricated to test the polarization resistance of the cathode using electrochemical impedance spectroscopy (EIS).;Cathode material nanopowder mixtures of Ce_0.8Gd_0.2O _1.9 (GDC) and La_0.6Sr_0.4Co_0.2Fe _0.8O₃ (LSCF6428) with different mass ratio, such as 30wt%:70wt% and 60wt%:40wt% of GDC:LSCF, were obtained. The composite nanopowders exhibit a perovskite structure of LSCF6428 and a fluorite structure of GDC and the two phases are homogeneously dispersed. The nanoparticles are almost globular in shape with a diameter from 10 nm to 60 nm and with BET specific areas around 20 m2/g. Homogeneous cauliflower-structure composite cathodes were obtained by both SPS and SolPS methods. The potentials of these two deposition technologies to provide functionally graded composite cathode with high homogeneity were demonstrated. Compared to SolPS cathodes, the SPS cathodes have finer nanostructure, higher porosity and better distributed pores, which takes advantage of the homogeneously distributed nanosized powders in the precursors. The SPS coatings were expected to have enlarged triple phase boundaries.;Key Words: Nanocomposite powder, GDC, LSCF, Suspension Plasma Spray (SPS), Solution Plasma Spray (SolPS), IT-SOFC, Induction Plasma, nanostructured composite cathode.