In this study, Lithium iron oxide (LiFeO₂ – LFO) was investigated as a new anode material for the high temperature SOFCs. From the DC conductivity measurement in argon containing 5% H₂, LFO exhibits good electronic conductivity of 5.08 Scm⁻¹ at 650 °C. LFO poses a high TEC value of 19.5 x 10⁻⁶ K⁻¹ in air. However, the TEC values of the commonly used 8YSZ and CGO electrolytes are much lower, 10.5 x 10⁻⁶ K⁻¹ and 12.5 x 10⁻⁶ K⁻¹ respectively. In order to resolve the mismatch in the TEC values between the electrode and the electrolyte, button fuel cells were fabricated via tape casting. LFO was infiltrated onto the porous and stable scaffold. Presently, the predominant electrolyte material used for the high temperature SOFC is 8YSZ. Due to this reason, the initial performance of LFO as an anode material was tested on tape-cast 8YSZ electrolyte-supported cell. The 8YSZ electrolyte-supported infiltrated with 30 wt% LFO for the anode and 40 wt% LSF for the cathode achieved a maximum power density of 50 mWcm⁻² at 700 °C in humidified H₂. Increasing the weight loading of LFO to 40 wt% worsen the performance. XRD pattern of the sintered powder containing 50 wt% LFO and 50 wt% 8YSZ confirmed that LFO and 8YSZ react with each other. CGO was considered as an alternative electrolyte material to 8YSZ. XRD pattern of the sintered powder containing 50 wt% LFO and 50 wt% CGO confirmed that they are compatible with each other. The CGO electrolyte supported cell infiltrated with 40 wt% LFO for the anode and 40 wt% LSC for the cathode achieved a maximum power density of 180 mWcm⁻² at 650 °C in humidified H₂. The addition of 10 wt% ceria to the LFO anode enhances the electrochemical activities of the cell. However, the overall performance of the cell decreased due to a larger increase in the series resistance. Since CGO electrolyte is easily reduced when testing at temperature higher than 550 °C, LSGM was used to increase the testing temperature. The 245 µm thick LSGM electrolyte-supported cell infiltrated with 40 wt% LSC and 30 wt% LFO obtained a maximum power density of 227 mWcm⁻² at 700 °C in humidified H₂. Decreasing the electrolyte thickness from 245 µm to 130 µm increased the performance of the cell. The 130 µm LSGM electrolyte-supported cell infiltrated with 40 wt% LSC and 30 wt% LFO was tested with the carbon/carbonate fuel as a HDCFC. Performance measurements of the cell was conducted at 650 °C and 700 °C with N₂ flowing at 20 ml/min. The cell performed better when testing at higher temperature. Recently, there has been great interest in developing a SOFC system for the cogeneration of electricity and valuable C₂ chemicals. The catalytic testing for oxidative methane coupling of methane revealed a high C₂ selectivity for the LFO powder. Cell testing of a sample infiltrated with 40 wt% LSC and 30 wt% LFO also achieved a methane conversion of ~3% and a C₂ selectivity of ~80% in methane at 700 °C.

Solid oxide fuel cells (SOFCs) have attracted much interest as the most efficient electrochemical device to directly convert chemical energy to usable electrical energy. The porous Ni-YSZ anode known as the state-of-the-art cermet anode material is found to show serious degradation when using hydrocarbon as fuel due to carbon deposition, sulphur poisoning, and nickel sintering. In order to overcome these problems, doped strontium titanate has been investigated as a potential anode material due to its high electronic conductivity and stability in reducing atmosphere. In this work, A-site deficient strontium titanate co-doped with lanthanum and calcium, La₀.₂Sr₀.₂₅Ca₀.₄₅TiO₃ (LSCT[sub](A-)), was examined. Flat multilayer ceramics have been produced using the aqueous tape casting technique by controlling the sintering behaviour of LSCT[sub](A-), resulting in a 450µm thick porous LSCT[sub](A-) scaffold with a well adhered 40µm dense YSZ electrolyte. Impregnation of CeO₂ and Ni results in a maximum power density of 0.96Wcm⁻² at 800°C, higher than those of without impregnation (0.124Wcm⁻²) and with impregnation of Ni alone (0.37Wcm⁻²). The addition of catalysts into LSCT[sub](A-) anode significantly reduces the polarization resistance of the cells, suggesting an insufficient electrocatalytic activity of the LSCT[sub](A-) backbone for hydrogen oxidation, but LSCT[sub](A-) can provide the electronic conductivity required for anode. Later, the cells with the configuration of LSCT[sub](A-)/YSZ/LSCF-YSZ were prepared by the organic tape casting and impregnation techniques with only 300-m thick anode as support. The effects of metallic catalysts in the anode supports on the initial performance and stability in humidified hydrogen were discussed. The nickel and iron impregnated LSCT[sub](A-) cell exhibits a maximum powder density of 272mW/cm² at 700°C, much larger than 43mW/cm² for the cell without impregnation and 112mW/cm² for the cell with nickel impregnation. Simultaneously, the bimetal Ni-Fe impregnates have significantly reduced the degradation rates in humidified hydrogen (3% H₂O) at 700°C. The enhancement from impregnation of the bi-metal can possibly be the result of the presence of ionic conducting Wustite Fe₁₋ₓO that resides underneath the Ni-Fe metallic particles and better microstructure. Third, in order to improve the ionic conductivity of the anode support and increase the effective TPBs, ionic conducting ceria was impregnated into the LSCT[sub](A-) anode, along with the metallic catalysts. The CeO₂-LSCT[sub](A-) cell shows a poor performance upon operation in hydrogen atmosphere containing 3% H₂O; and with addition of metallic catalysts, the cell performance increases drastically by almost three-fold. However, the infiltrated Ni particles on the top of ceria layer cause the deposition of carbon filament leading to cell cracking when exposure to humidified methane (3% H₂O). No such behaviour was observed on the CeO₂-NiFe impregnated anode. The microstructure images of the impregnated anodes at different times during stability testing demonstrate that the grain growth of catalysts, the interaction between the anode backbone and infiltrates, and the spalling of the agglomerated catalysts are the main reasons for the performance degradation. Fourth, the YSZ-LSCT[sub](A-) composites including the YSZ contents of 5-80wt.% were investigated to determine the percolation threshold concentration of YSZ to achieve electronic and ionic conducting pathways when using the composite as SOFC anode backbone. The microstructure and dilatometric curves show that when the YSZ content is below 30%, the milled sample has a lower shrinkage than the unmilled one due to the blocking effect from the well distributed YSZ grains within LSCT[sub](A-) bulk. However, at the YSZ above 30% where two phases start to form the individual and interconnected bulk, the composites without ball milling process show a lower densification. The impact of YSZ concentration and ball milling process on the electrical properties of the composites reveals that the percolation threshold concentration is not only dependant on the actual concentration, but also related to the local arrangement of two phases. In Napier University, the electroless nickel-ceramic co-depositon process was investigated as a manufacturing technique for the anodes of planar SOFCs, which entails reduced costs and reduced high-temperature induced defects, compared with conventional fabrication techniques. The Ni-YSZ anodes prepared by the electroless co-deposition technique without the addition of surfactant adhere well to the YSZ electrolyte before and after testing at 800°C in humidified hydrogen. Ni-YSZ anodes co-deposited with pore-forming starch showed twice the maximum power density compared with those without the starch. It has therefore been demonstrated that a porous Ni-YSZ cermet structure was successfully manufactured by means of an electroless plating technique incorporating pore formers followed by firing at 450°C in air. Although the use of surfactant (CTAB) increases the plating thickness, it induces the formation of a Ni-rich layer on the electrolyte/anode interface, leading to the delamination of anode most likely due to the mismatched TECs with the adjacent YSZ electrolyte.

Células a combustível de óxido sólido são sistemas capazes de gerar energia elétrica por meio da oxidação de moléculas hidrogenadas. Normalmente os sistemas planares e tubulares, são compostos por quatro constituintes bem definidos: cátodo, ânodo, eletrólito e selante. Este último componente é o foco do presente estudo, sendo que suas principais características são estabilidade química na temperatura de operação da célula, isolamento elétrico e coeficiente de expansão térmica compatível com os outros constituintes, além da viscosidade elevada e resistência química em atmosferas oxidantes e redutoras. Devido à geometria planar e de multicamadas da célula se optou por usar como selante vidros niobofosfatos. A selagem foi realizada a partir de dispersão de pó de vidro em álcool etílico, gerando uma solução viscosa que foi aplicada sobre o substrato. Posteriormente realizou se um tratamento térmico para a consolidação do selamento. Os vidros estudados foram denominados de Nb30, Nb37, Nb40 e Nb44, de acordo com o teor nominal de óxido de nióbio utilizado na composição. O objetivo desse trabalho foi caracterizar, a partir de precursores os selantes a base de vidros niobofosfatos para aplicar em células a combustível de óxido sólido do tipo planar. Foram feitos caracterizações dos pós dos vidros e de pastilhas cristalizadas para determinar os coeficientes de expansão térmica (CET), resistividade elétrica, difração de raio X e microscopia eletrônica de varredura (MEV), além de, caracterizar visualmente sua adesividade, molhabilidade, resistência mecânica em substratos de alumina e em conjunto com os componentes das SOFC, sendo também testados os selantes em operação nas unidades previamente formadas de SOFC (ciclos térmicos). / Solid oxide fuel cells (SOFC) are devices which generate d.c. power by the oxidation of hydrogen molecules. These devices can have a multilayer plane design containing a cathode, an anode, a solid electrolyte, and a sealing material. The sealing, which is the subject of this study, has to be chemically stable at relatively SOFC operational condition in oxi-redox atmospheres, electrical insulator, with a thermal expansion coefficient matching other components, and, in of glass, the viscosity must be relatively high. The aim of the present work is to characterize niobophosphate glasses which will be used as sealant precursors of Solid Oxide Fuel Cell with a plane design. Niobophosphate glasses, named Nb30, Nb37, Nb40, and Nb44 according to the niobium content, were investigated for this purpose. The sealing was performed by mixing glass powder with ethanol which was applied over the substrate. Later, a heat treatment was performed to consolidate the sealing. Glass powder and devitrified glass pellets were characterized by different techniques. The thermal expansion coefficient, electrical resistivity, and the X-rays diffraction pattern were determined for these materials. Scanning electron microscopy was also used to visualize the sealing/ substrate interface, and to evaluate the adhesiveness, wetability, apparent mechanical resistance in alumina substrates and in other SOFC components. The sealants were tested in SOFC, and also submitted to simulating thermal cycles.

The research into materials for use as cathode materials for solid oxide fuel cells (SOFC) is ongoing, with many different avenues being investigated. Copper based delafossites were studied for cathode side applications in SOFCs, as a novel and comparatively cheap material. The aim was to identify suitable materials with appropriate electrical conductivity, thermal, chemical and mechanical stability in air. Furthermore, understanding the behaviour of the delafossites during the thermal oxidation to spinel and copper oxide would be beneficial to further development of the materials. The structure and properties of the copper based delafossites CuFeO₂, CuAlO₂ and CuCrO₂ were studied, alongside several doped compositions for each parent composition. The electronic conductivity of the CuFeO₂ family was improved by doping fluorine into the structure, with 1 atomic % doping producing ~3.8 S cm⁻¹ at 800 °C. However, as reported in literature the structure is vulnerable to oxidation at higher temperatures. In contrast, CuAlO₂ was stable over the SOFC temperature range, and therefore had appropriate thermal expansion coefficients (TEC) of ~11 x 10⁻⁶ K⁻¹, but relatively low electronic conductivity. CuCrO₂ compositions had good overall TECs, but aliovalent doping of Mg²⁺ improved the conductivity to ~17.1 S cm⁻¹ at 800°C for 2.5 atomic % doped CuCrO₂. Neutron diffraction was utilised to study members of the solid solution CuFe₁₋ₓCrₓO₂ (x = 0, 0.25 and 0.5) during in-situ oxidation at high temperature. Points of positive scattering density were identified within the CuFeO₂ structure, which were attributed to the location of the intercalated oxygen ions before the transformation proceeded. Additionally, the cation distribution between the tetrahedral and octahedral sites within the developing spinel were characterised for x = 0, and partially for the x = 0.25 and 0.5 compositions using complimentary XRD patterns. Finally, magnesium doped CuCrO₂ delafossites were used in several different preliminary symmetrical cells for study using electrochemical impedance spectroscopy (EIS). Pure delafossite inks gave relatively large area specific resistance (ASR) values, 1.29 - 2.69 Ω cm² at 800 °C. It was attempted to improve upon these values through infiltration of CeO₂ and through change in microstructure using composite type inks, without much success. Inks using CuCr₀.₈Fe₀.₂O₂ were also tested as both a single phase electrode and as a composite type electrode. The pure delafossite electrode still had a large ASR value, (~33.4 Ω cm² at 800 °C) while composite electrodes obtained much more respectable ASR values ~0.75 Ω cm² at 800 °C.

Células a combustível de óxido sólido são sistemas capazes de gerar energia elétrica por meio da oxidação de moléculas hidrogenadas. Normalmente os sistemas planares e tubulares, são compostos por quatro constituintes bem definidos: cátodo, ânodo, eletrólito e selante. Este último componente é o foco do presente estudo, sendo que suas principais características são estabilidade química na temperatura de operação da célula, isolamento elétrico e coeficiente de expansão térmica compatível com os outros constituintes, além da viscosidade elevada e resistência química em atmosferas oxidantes e redutoras. Devido à geometria planar e de multicamadas da célula se optou por usar como selante vidros niobofosfatos. A selagem foi realizada a partir de dispersão de pó de vidro em álcool etílico, gerando uma solução viscosa que foi aplicada sobre o substrato. Posteriormente realizou se um tratamento térmico para a consolidação do selamento. Os vidros estudados foram denominados de Nb30, Nb37, Nb40 e Nb44, de acordo com o teor nominal de óxido de nióbio utilizado na composição. O objetivo desse trabalho foi caracterizar, a partir de precursores os selantes a base de vidros niobofosfatos para aplicar em células a combustível de óxido sólido do tipo planar. Foram feitos caracterizações dos pós dos vidros e de pastilhas cristalizadas para determinar os coeficientes de expansão térmica (CET), resistividade elétrica, difração de raio X e microscopia eletrônica de varredura (MEV), além de, caracterizar visualmente sua adesividade, molhabilidade, resistência mecânica em substratos de alumina e em conjunto com os componentes das SOFC, sendo também testados os selantes em operação nas unidades previamente formadas de SOFC (ciclos térmicos). / Solid oxide fuel cells (SOFC) are devices which generate d.c. power by the oxidation of hydrogen molecules. These devices can have a multilayer plane design containing a cathode, an anode, a solid electrolyte, and a sealing material. The sealing, which is the subject of this study, has to be chemically stable at relatively SOFC operational condition in oxi-redox atmospheres, electrical insulator, with a thermal expansion coefficient matching other components, and, in of glass, the viscosity must be relatively high. The aim of the present work is to characterize niobophosphate glasses which will be used as sealant precursors of Solid Oxide Fuel Cell with a plane design. Niobophosphate glasses, named Nb30, Nb37, Nb40, and Nb44 according to the niobium content, were investigated for this purpose. The sealing was performed by mixing glass powder with ethanol which was applied over the substrate. Later, a heat treatment was performed to consolidate the sealing. Glass powder and devitrified glass pellets were characterized by different techniques. The thermal expansion coefficient, electrical resistivity, and the X-rays diffraction pattern were determined for these materials. Scanning electron microscopy was also used to visualize the sealing/ substrate interface, and to evaluate the adhesiveness, wetability, apparent mechanical resistance in alumina substrates and in other SOFC components. The sealants were tested in SOFC, and also submitted to simulating thermal cycles.

Metallic interconnects in intermediate temperature solid oxide fuel cells (IT-SOFC) stacks form Cr2O3 scales on their surface. Such oxide scales can be further oxidized to Cr6+ containing gaseous species that migrate and deposit at the cathode triple phase boundaries, causing significant degradation in the performance of the SOFCs. This phenomenon is termed as ‘Cr-poisoning’. A solution to this problem is the application of coatings on the interconnects that act as a diffusion barrier to Cr migration. Two different Cu/Mn spinel compositions, Cu1.3Mn1.7O4 and CuMn1.8O4, were studied as coating materials. Dense coatings were deposited on both flat plates and meshes by electrophoretic deposition (EPD) followed by subsequent thermo-mechanical or thermal densification steps. At room temperature, Cu1.3Mn1.7O4 coatings were found to have a mixture of CuO and spinel phases, while CuMn1.8O4 coatings were found to have a mixture of Mn3O4 and spinel phases. However, CuMn1.8O4 is a pure spinel phase between 750 °C and 850 °C. After densification processing and high temperature oxidation, a Cr2O3 layer was formed at the coating/alloy interface, which partially reacted with the spinel coatings to form a dense cubic spinel layer of the general composition (Cu,Mn,Cr)3-xO4. In addition, Cr-rich precipitates, formed in the dense layer close to coating/alloy interface. It is believed that these are Cr2O3 precipitates, formed when the solubility of Cr in the spinel phase is reached. Solubility experiments using powders showed that 1 mole of CuMn1.8O4 can effectively getter 1.83 moles of Cr2O3 at 800°C. Electrical conductivity of (Cu,Mn,Cr)3-xO4 was found to be at least two orders of magnitude higher than that of Cr2O3. The coatings acted as an effective Cr getter whose lifetime depends on the oxidation temperature, coating thickness, and the overall porosity in the coating. In-cell electrochemical testing showed that the CuMn1.8O4 coatings on Crofer 22 APU meshes performed significantly better than commercial Cu/Mn spinel coatings. The CuMn1.8O4 coatings gettered Cr effectively for 12 days at 800 ºC, leading to no performance loss of the cell due to Cr-poisoning. Significantly longer lifetime can be achieved at 750 ºC or lower, which is the target operational temperature regime of IT-SOFCs.

Les piles à combustible sont des systèmes qui permettent de convertir directement de l'énergie chimique en énergie électrique. La structure physique d'une pile à combustible est composée d'une cathode et d'une anode poreuses séparées par un électrolyte dense. Les piles à combustible à oxydes solides (Solid Oxide Fuel Cell (SOFC))offrent une alternative intéressante pour la production d'énergie et une certaine polyvalence dans leur utilisation. Les recherches actuelles se focalisent sur l'abaissement de la température de fonctionnement de ce type de pile (500-700°C) pour augmenter leur durée de vie, diminuer les coûts de fabrication et les dégradations aux interfaces. Afin de compenser ces problèmes, la recherche tend vers des matériaux présentant de meilleures propriétés électrochimiques ou en modifiant la microstructure de la cathode pour améliorer le transfert de masse et le transfert de charge. La cathode est une couche très importante dans la pile SOFC car elle présente une résistance de la polarisation dont la réduction constitue un défi important à traiter. Dans une première partie de ce travail de thèse nous avons développé une méthode pour permettre d'améliorer les propriétés électrochimiques de cathodes de manganite de lanthane dopée au strontium (LSM). La seconde partie a été consacrée à l'élaboration et la caractérisation par spectroscopie d'impédance de demi-cellules symétriques de SOFC avec un matériau composite à base de LSM permettant d'améliorer les propriétés électrochimiques des électrodes à des températures comprises entre 600 °C - 700 °C. / Fuel cells are systems that convert chemical energy directly into electrical energy. The physical structure of a fuel cell is composed of a porous cathode and anode separated by a dense electrolyte. Solid Oxide Fuel Cells (SOFC) offer an alternative for power generation and versability in their use. Current research focuses on lowering the operating temperature of this type of fuel cell (500-700°C) to increase their life, reduce manufacturing costs and damageto the interfaces. In order to compensate these problems, research tends towards materials with better electrochemical properties or by modifying the microstructure of the cathode to improve mass transfer and charge transfer. The cathode is a very important layer in the SOFC stack because it has a polarization resistance whose reduction is a major challenge to deal with. In a first part of this thesis work we have developed a method to improve the electochemical properties of strontium doped lanthanum manganite (LSM) cathodes. The second part was devoted to the elaboration and caracterization by impedance spectroscopy of SOFC symmetric half-cells with a LSM-based composite material allowing to improve the electochemical properties of electrodes at temperatures between 600-700 °C.

The traditional aluminum production process (Hall-Héroult process) involves electrolyzing the alumina dissolved in the molten cryolite salt. This process is energy intensive and emits massive amounts of CO2 and other greenhouse gases. The market demand of aluminum and the environmental impact of the current aluminum production process justify research and development of alternative electrolytic processes for aluminum production that can both reduce the cost and eliminate adverse environment impacts. Solid oxide membrane (SOM) based electrolysis process is an innovative technology that has been demonstrated to successfully produce many energy-intensive metals directly from their oxides in an efficient, economical and environmentally sound way. During the SOM electrolysis process, an oxygen-ion-conducting SOM tube made of ytteria-stabilized zirconia (YSZ) separates the pre-selected molten flux with dissolved metal oxide from the inert anode assembly inside the YSZ tube. When the applied DC potential between the cathode and the anode exceeds the dissociation potential of desired metal oxide, the metal is reduced at the cathode while oxygen ions migrate through the YSZ membrane and are oxidized at the anode. Employing the inert anode allows the oxygen to be collected at the anode as a value added byproduct. In this work, a zero-direct-carbon-emission aluminum production process utilizing SOM electrolysis is presented. The molten flux used in the electrolysis process is optimized through careful measurements of its physio-chemical properties. The liquidus temperature, volatilization rate, alumina solubility, aluminum solubility, YSZ membrane degradation rate and electrical conductivity of various flux compositions were measured, and the flux chosen for SOM electrolysis was a eutectic MgF2-CaF2 system containing optimized amounts of YF3, CaO and Al2O3. Laboratory scale SOM electrolysis employing the inert anode were performed at 1100 ~ 1200oC to demonstrate the feasibility of producing and collecting aluminum while producing pure oxygen as a byproduct. The aluminum product was characterized by scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). An equivalent circuit model for the electrolysis process was developed in order to identify the polarization losses in the SOM electrolysis cell. / 2016-12-21T00:00:00Z

Single step co-sintering is proposed as a method to minimise the time and cost of fabricating solid oxide fuel cells (SOFCs). Such a methodology is attractive but challenging due to the differing sintering behaviours and thermal mismatch of the constituent materials of the anode, cathode and electrolyte in solid oxide fuel cells. As a result it is likely that compromises are made for one layer with respect to optimising another. The single chamber solid oxide fuel cell (SC-SOFC) has not seen widespread adoption due to poor selectivity and fuel utilisation, but relaxed some of the stringent SOFC requirements such as sealing, and the need for a dense electrolyte layer. Thus, to initiate the study into single step co-sintering, the single chamber SOFC is earmarked as the first candidate. The effect of single step co-sintering on cell performance is also an attractive area to investigate. Therefore, in this study, a new co-sintering process (single step co-sintering) was applied to fabricate three different types (in terms of the supporting structure) of planar SC-SOFCSs (the anode, cathode and electrolyte supported planar cells) and anode supported wavy types of SC-SOFC in order to reduce fabrication cost and time owing to effective fabrication process. In addition, their performances were tested to establish functionality of the sintered specimens as working electrochemical cells as well as to investigate the maximum performance possible with these cells under single chamber conditions. Moreover, it is also aimed to improve the performance of SC-SOFCs by extending TPB (Triple phase boundary) via wavy type. This study presents a single step co-sintering manufacturing process of planar and wavy single chamber solid oxide fuel cells with porous multilayer structures, consisting of NiO-CGO, CGO and CGO-LSCF as anode, electrolyte and cathode respectively. Pressure of 2 MPa, with the temperature at 60˚C for 5 minutes, was deemed optimal for the hot pressing of these layers. The best result of sintering profile was obtained with heating rate of 1˚C min-1 to 500˚C, 2˚C min-1 to 900˚C and 1˚C min-1 to 1200˚C with 1 hour dwelling; the cooling rate was 3˚C min-1. Hence anode supported SC-SOFC (thickness: 200:40:40 µm, thickness ratio: 10:2:2, anode (A): electrolyte (E): cathode (C)) was fabricated via a single co-sintering process, albeit with curvature formation at edges. Its performance was investigated in methane-oxygen mixtures at a temperature of 600˚C. Maximum open circuit voltage (OCV) and power density of the anode supported planar cell were obtained as 0.69 V and 2.83 mW cm-2, respectively, at a fuel-oxygen ratio of 1. Subsequently, anode thickness was increased to 800 µm and electrolyte thickness was reduced 20 µm (thickness ratio of cell 40:1:2) to obtain curvature-free anode-supported SOFCs with the help of a porous alumina cover plate placed on the top of the cell. The highest power density and OCV obtained from this cell was 30.69 mW cm-2 and 0.71 V, respectively, at the same mix ratio. In addition, the maximum residual stresses between cathode end electrolyte layers of anode supported cells after sintering were investigated using the fluorescence spectroscopy technique. The total mean residual stresses along the x-direction of the final anode supported planar cell after sintering were measured to range from -488.688 MPa to -270.781 MPa. Determination of optimum thickness and thickness ratio of the cell with the defined ideal hot pressing and sintering conditions for single step co-sintering were carried out for cathode and electrolyte supported planar cells using similar fabrication processes. Their performance changes with thickness ratio were examined. The results show that the cathode and electrolyte supported planar cells can be obtained successfully via single step co-sintering technique with the help of alumina cover plates, as with the anode supported cell. In addition, an anode supported wavy SC-SOFC was fabricated via single step co-sintering and its performance was also investigated. The maximum power density and OCV from the final curvature free cathode supported planar cell (thickness: 60:20:800 µm, thickness ratio: 3:1:20, A:E:C) was measured to be 1.71 mW cm-2 and 0.20 V, respectively, at a fuel-oxygen ratio of 1.6. Likewise, the maximum OCV and power density were found to be 0.55 V and 29.39 mW cm-2, respectively, at a fuel-oxygen ratio of 2.6, for the final electrolyte supported curvature free planar cell (thickness: 60:300:40 µm, thickness ratio: 3:15:2, A:E:C). Furthermore, a maximum OCV of 0.43 V and power density of 29.7 mW cm-2 were found from the final anode supported wavy cell (thickness: 800:20:40 µm, thickness ratio: 40:1:2, A:E:C) at a fuel-oxygen ratio of 1. In essence, this study can be divided into five chapters. The first chapter addresses the overview of the research background, problem statement, aims and objective of this study as well as that of novelty and impact. In the second chapter, fundamental information is provided regarding SOFCs and SC-SOFCs in terms of working principles, main components including electrodes electrolytes, advantages and disadvantages, types, material used for each cell components, losses in the system, and so forth. Moreover, the second chapter also contains essential sintering information in order to understand how to approach sintering of ceramics or cermet to fabricate SC-SOFCs. The overall methodology of this study is explained in detail in the third chapter while experimental works are described in the chapter 4, chapter 5, chapter 6, chapter 7 and chapter 8. Chapter 5 also contains background for the fluorescence spectroscopy and a modelling technique for residual stress measurement between ceramic layers. The results of experiments with discussion session are also in the same chapter. The last chapter presents conclusions and the possible routes for future works of the study.

Solid Oxide Fuel Cells (SOFCs) are devices that directly convert chemical energy into electrical energy, without proceeding through a Carnot combustion cycle. These devices are based on the usage of solid oxide electrolytes operating at relatively elevated temperatures. Two major hurdles must be overcome in order to decrease the operating temperatures of practical SOFCs. The first relates to reducing ohmic losses within solid electrolytes. The second relates to the need for developing high performance electrodes since electrolyte reaction rates at both anode and cathode are affected detrimentally as operating temperatures fall. This PhD project has focussed on addressing the first hurdle in two innovative ways: 1. the implementation of solid electrolytes with higher ionic conductivity than zirconia, 2. the development of very thin film electrolytes as thick as 5ƒÝm. Several thin films with novel electrode-electrolyte structures were fabricated and evaluated in order to demonstrate the viability of low temperature SOFC operations. Development of such thin films was innovative and challenging to achieve. The approach taken in this work involved fabricating a dense and thin gadolinia doped ceria (10GDC - Gd 10wt%, Ce 90wt%) oxide electrolyte. 10GDC is an electrolyte exhibiting higher conductivities than conventional materials during low temperature operations. A research contribution of this PhD was the demonstration of the deposition of 10GDC thin films using RF magnetron sputtering for the first time. 10GDC thin film electrolytes with thickness in a range between 0.1 to 5ƒÝm were fabricated on 10 yttrium stabilised zirconium (10YSZ) substrates by using a RF magnetron sputterer. The primary parameters controlling 10GDC thin film deposition using this method were explored in order to identify optimal conditions. The fabricated films were subsequently analysed for their morphology, composition and stoichiometry using a variety of methods, including Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray Spectrometry (EDS), optical microscopy, X-ray Photoelectron Spectroscopy (XPS), and X-ray Diffraction (XRD). A preliminary test was conducted in order to examine the function of 10GDC thin film electrolytes together with the cathode and anode substrates at intermediate temperatures (700oC). A complete planar single cell was designed and assembled for this purpose. However, when fully assembled and tested, the cell failed to generate any voltage or current. Consequently, the remainder of the PhD work was focused on systematically exploring the factors contributing to the assembled fuel cell failure. As fabrication failure analysis is seldom reported in the scientific literature, this analysis represents a significant scientific contribution. This analysis proceeded in a series of steps that involved several different methods, including SEM, red dye analysis, surface morphology and cross section analysis of the cell. It was found that pinholes and cracks were present during the fuel cell operating test. Cathode delamination was also found to have occurred during the test operation. This was determined to be due to thermal expansion mismatch between the cathode substrate and the 10GDC electrolyte thin film. A series of suggestions for future research are presented in the conclusion of this work.