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Solid oxide fuel cells (SOFCs) are promising power generation devices due to its high efficiency and low pollutant emissions. SOFCs operate with a wide range of fuels from hydrogen (H2) to hydrocarbons, and are mainly intended for stationary power generation. Compared to combustion systems, SOFCs have significantly lower environmental impacts. However, the full scale commercialization of SOFCs is impeded by high cost and problems associated with long-term performance and durability. The cell performance can be affected by various internal losses, involving cathode, anode and electrolyte. Anodic losses make a significant contribution to the overall losses, practically in anode-supported cells. Therefore, it is desirable to reduce the anodic losses in order to enhance the overall cell performance. Knowledge of the actual elementary reaction steps and kinetics of electrochemical reactions taking place on the anode is critical for further improvement of the anode performance. Since H2 and carbon monoxide (CO) are the primary reforming products when hydrocarbons are used as SOFC fuels, investigation of electrochemical reactions involving H2 and CO should provide a better understanding of SOFC electrochemical behavior with hydrocarbon feeds. However, still exist uncertainties concerning both H2 and CO electrochemical reactions. The overall objective of this research is to investigate the mechanistic details of H2 and CO electrochemical reactions on SOFC anodes. To achieve this objective, Ni/YSZ pattern anodes were used in the experimental study and as model anodes for the simulation work due to their simplified 2-D structure. The Ni/YSZ pattern anodes were fabricated using a bi-layer resist lift-off method. Imaging resist nLOF2035 and sacrificial resist PGMI SF11 were found to be effective in the bi-layer photolithographic process. Suitable undercut size was found critical for successful pattern fabrication. A simple method, involving taking microscopic photographs of photoresist pattern was developed, to check if the undercut size is large enough for the lift-off; semi-circle wrinkles observable in photographs indicate whether the undercut is big enough for successful pattern anode fabrication. The final product prepared by this method showed straight and clear Ni patterns. A systematic study was performed to determine the stable conditions for Ni/YSZ pattern anode performance. The microstructure and electrochemical behavior changes of the pattern anode were evaluated as a function of Ni thickness, temperature and H2O content in H2 environment. Ni/YSZ pattern anodes with 0.5 µm thick Ni were tested in dry H2 at 550°C without significantly changing the TPB line. Ni/YSZ pattern anodes with Ni thickness of 0.8 µm were tested at 550°C under dry and humidified H2 (3-70% H2O) conditions without TPB line change. For 0.8 µm thick patterns, the TPB length showed pronounced changes in the presence of H2 with 3-70% H2O at 700°C. Significant increase in TPB length due to hole formation was observed at 800°C with 3% and 10% H2O. Ni/YSZ pattern anodes with 1.0 µm thick Ni were stable in H2 with 3% H2O in the range 500-800°C, with only slight changes in the TPB line. Changes of TPB line and Ni microstructure were observed in the presence of 3-70% H2O above 700C. Stabilization of the pattern anode performance depends on temperature. To accelerate stabilization of the cell, pre-treatment of the cell in H2 with 3% H2O for ~22 hrs at 750°C or 800°C could be performed. In addition, comprehensive data sets for H2 and CO electrochemical oxidation reactions on Ni/YSZ pattern anodes were obtained under stable test conditions. For the H2/H2O system, the polarization resistance (Rp) increases as temperature, overpotential, H2 partial pressure, TPB length decreases. Rp is also dependent on H2O content. When the H2O content is between 3% and 30-40%, Rp decreased with increasing H2O content. However, Rp is less affected with further increases in H2O content. For the CO/CO2 system, polarization resistance depends on partial pressure of CO and CO2, temperature and overpotential. Moreover, the polarization resistance decreases when the partial pressure of CO2 and temperature increase. The partial pressure of CO has a positive effect on the polarization resistance. The polarization resistance decreases to a minimum when the overpotential is 0.1 V. For both H2 and CO electrochemical oxidations, charge transfer reactions contribute to the rate limiting steps. A 1-D dynamic SOFC half-cell model considering multiple elementary reaction kinetics was developed. The model describes elementary chemical reactions, electrochemical reactions and surface diffusion on Ni/YSZ pattern anodes. A new charge transfer reactions mechanism proposed by Shishkin and Ziegler (2010) based on Density Functional Theory (DFT) was investigated through kinetic modeling and pattern anode experimental validation. This new mechanism considers hydrogen oxidation at the interface of Ni and YSZ. It involves a hydrogen atom reacting with the oxygen ions bound to both Ni and YSZ to produce hydroxyl (charge transfer reaction 1), which then reacts with the other hydrogen atom to form water (charge transfer reaction 2). The predictive capability of this reaction mechanism to represent our experimental results was evaluated. The simulated Tafel plots were compared with our experimental data for a wide range of H2 and H2O partial pressures and at different temperatures. Good agreements between simulations and experimental results were obtained. Charge transfer reaction 1 was found to be rate-determining under cathodic polarization. Under anodic polarization, a change in rate-limiting process from charge transfer reaction 1 to charge transfer reaction 2 was found when increasing the H2O partial pressure. Surface diffusion was not found to affect the H2 electrochemical performance.

Atmospheric plasma spraying is attractive for manufacturing solid oxide fuel cells (SOFCs) because it allows functional layers to be built rapidly with controlled microstructures. The technique allows SOFCs that operate at low temperatures (600 to 750°C) to be fabricated by spraying directly onto robust and inexpensive metallic supports. Processes were developed to manufacture metal-supported SOFC cathodes by axial-injection plasma spraying. Cathodes consisted of LSCF (La0.6Sr0.4Co0.2Fe0.8O3-δ) or SSC (Sm0.5Sr0.5CoO3) as the primary material. Initially, the plasma spray process parameters were varied, and x-ray diffraction analyses were performed on the cathode coatings to detect material decomposition and the formation of undesired phases. These results determined the envelope of plasma spray parameters in which coatings of LSCF and SSC can be manufactured, and the range of conditions in which composite cathode coatings could potentially be manufactured. Subsequently, composite cathodes were fabricated by mixing up to 40 wt. % of the ionic conducting SDC (Ce0.8Sm0.2O1.9) material into the feedstock. The deposition efficiencies of these cathodes were calculated based on the mass of the sprayed cathode. Particle surface temperatures were measured in-flight to enhance understanding of the relationship between spray parameters, microstructure, and deposition efficiency. Electrochemical impedance spectroscopy was performed in symmetrical cells: at 750°C, LSCF-SDC cathodes had polarization resistances as low as 0.101 Ωcm², and SSC cathodes had polarization resistances as low as 0.0056 Ωcm². Finer mixing of the ceramic phases was achieved by using a nano-structured feedstock that contained both LSCF and SDC phases agglomerated together in larger particles. Fuel cells containing a yttria-stabilized zirconia (YSZ) electrolyte and a nickel-YSZ anode were fabricated, and the effect of the cathode microstructure on cell impedance was studied using the analysis of differential impedance spectra. The degradation of composite LSCF-SDC cathodes on porous 430 stainless steel supports was also investigated. To reduce degradation, La2O3 and Y2O3 reactive element oxide coatings were deposited on the internal pore surfaces of the metal supports. As a result, polarization resistance degradation rates as low as 0.00256 Ω·cm2 /1000 h were observed over 100 hours on coated substrates, compared to 0.1 Ω·cm2 /1000 h on uncoated substrates.

Atmospheric plasma spraying is attractive for manufacturing solid oxide fuel cells (SOFCs) because it allows functional layers to be built rapidly with controlled microstructures. The technique allows SOFCs that operate at low temperatures (600 to 750°C) to be fabricated by spraying directly onto robust and inexpensive metallic supports. Processes were developed to manufacture metal-supported SOFC cathodes by axial-injection plasma spraying. Cathodes consisted of LSCF (La0.6Sr0.4Co0.2Fe0.8O3-δ) or SSC (Sm0.5Sr0.5CoO3) as the primary material. Initially, the plasma spray process parameters were varied, and x-ray diffraction analyses were performed on the cathode coatings to detect material decomposition and the formation of undesired phases. These results determined the envelope of plasma spray parameters in which coatings of LSCF and SSC can be manufactured, and the range of conditions in which composite cathode coatings could potentially be manufactured. Subsequently, composite cathodes were fabricated by mixing up to 40 wt. % of the ionic conducting SDC (Ce0.8Sm0.2O1.9) material into the feedstock. The deposition efficiencies of these cathodes were calculated based on the mass of the sprayed cathode. Particle surface temperatures were measured in-flight to enhance understanding of the relationship between spray parameters, microstructure, and deposition efficiency. Electrochemical impedance spectroscopy was performed in symmetrical cells: at 750°C, LSCF-SDC cathodes had polarization resistances as low as 0.101 Ωcm², and SSC cathodes had polarization resistances as low as 0.0056 Ωcm². Finer mixing of the ceramic phases was achieved by using a nano-structured feedstock that contained both LSCF and SDC phases agglomerated together in larger particles. Fuel cells containing a yttria-stabilized zirconia (YSZ) electrolyte and a nickel-YSZ anode were fabricated, and the effect of the cathode microstructure on cell impedance was studied using the analysis of differential impedance spectra. The degradation of composite LSCF-SDC cathodes on porous 430 stainless steel supports was also investigated. To reduce degradation, La2O3 and Y2O3 reactive element oxide coatings were deposited on the internal pore surfaces of the metal supports. As a result, polarization resistance degradation rates as low as 0.00256 Ω·cm2 /1000 h were observed over 100 hours on coated substrates, compared to 0.1 Ω·cm2 /1000 h on uncoated substrates.

A series of cermet powders of composition NixCo(1-x)O-YSZ were synthesized for testing as cermet anode materials for SOFCs. The Co is found by powder XRD to become incorporated into the crystal lattice of the NiO, thus forming a true alloyed material. SEM and EDS results show two types of particles upon sintering to 1380oC: small, amorphous particles of YSZ and large, crystalline particles of nickel. The electrochemical oxidation of hydrogen on a cermet anode composed of Ni0.7Co0.3O-YSZ was investigated using a series of many button cells. Through EIS data, cyclic voltammetry data, the exchange current densities for these button cells were determined. Although a relatively large variation was found (expected to be due to microstructural variation) the average values for both methods of measurement is in good agreement in hydrogen. Following reduction in pure hydrogen, the fuel was changed to a mixture with high concentration of H2S. It was found that a concentration of 10 % H2S/H2 produced a sudden change in anode microstructure and resulted in loss of exchange current density. Lowering the amount of H2S in the initial fuel feed, which allowed for a more gradual microstructural change, allowed the cell to eventually function at concentrations in excess of 10 % H2S/H2. It was determined by OCV values in various concentrations of H2S/H2 that hydrogen is the predominant fuel of choice, even if H2S is available. Following electrochemical testing, slow cooling in a 10 % H2S/H2 mixture following produced metal sulfide spheres, as determined by SEM and EDS. Investigation in hydrocarbon, alcohol and biodiesel fuels was then undertaken to test the fuel variability of the given cermet anode material. Methane containing 10 % H2S was found to have increased exchange current density relative to poisoned hydrogen. Ethane and biodiesel experienced no increase in exchange current density, but a lengthening of the functional lifetime of the cell was observed, indicating reduced carbon poisoning. Methanol is a promising oxygen-containing SOFC fuel since it produced exchange current density values larger than hydrogen, and showed no evidence of coke formation by post-mortem SEM. Since oxygen-containing fuels are known to decompose in the gas phase at typical SOFC operating temperatures, the performance in a mixture of various CO/H2 fuels was then investigated. The Ni0.7Co0.3O-YSZ cermet anode gave higher exchange current density values for low ratio of CO/H2 fuels in the range 20/80 and 30/70 compared to pure H2. This is the first example of a Ni-based anode providing higher performance with a CO/H2 mixed fuel than for a pure H2 fuel. Finally, continuous running of a cell with fuel ratio 25/75 CO/H2 for 7 days produced exchange current density values, which were observed to increase significantly above the values for pure H2 during days 1-4 followed by deterioration below the value for hydrogen on subsequent days.

A new reactor and a novel in-situ sampling technique were developed for the study of the synthesis of CeO2 powders produced from dissolved cerium nitrate salts. The reactor minimized particle recirculation and provided a highly symmetric and undisturbed plasma flow suitable for the analysis of the phenomena affecting the formation of CeO2 powders. The sampling probe provided in-situ sampling of in-flight CeO2 particles and allowed continuous sampling without cross contamination. The sampled particles were collected using a wet collection system composed of a mist atomizer acting as a scrubber and a custom-made spray chamber. The entire collection system is portable and it was tested in the particle range of 20 nm to 100 mum. This information provided a picture of how CeO2 particles were formed. A numerical simulation of different plasma operating parameters using Fluent was presented. A comprehensive droplet-to-particle formation mechanism was deduced based on calorimetry, thermodynamics of CeO2 formation, numerical simulations and collected particles. The effect of adding water soluble fuels (alanine and glycine) to the original cerium nitrate solutions was investigated. Fuel addition decreased the temperature of CeO2 formation by acting as a local heat source as a result of fuel auto-ignition. The addition of fuel caused "particle size discrimination", and a single mode particle size distribution centered between 50-140 nm was achieved along the centerline of the reactor. / Also, heat and mass transfer effects were numerically investigated in evaporating solution droplets (20-40 mum in diameter) containing dissolved hexahydrated cerium nitrate in a stationary rf Ar-O2 thermal plasma. This model was developed to study the evaporation of a solution droplet surrounded by a porous crust in a stagnant rf Ar-O2 thermal plasma under reduced pressure. It considered a three phase system: a liquid core of dissolved Ce(NO 3)3.6H2O in water, a dry porous crust of homogeneously precipitated spherical crystals of equal size, and an Ar-O2 plasma under reduced pressure. The impact of different plasma operating parameters on the temperature and dissolved solid content profiles in the droplet was studied, i.e. surrounding plasma temperature, initial salt content and droplet size, plasma gas composition, and system pressure. Temperature and composition dependant thermophysical properties were used. The model was solved in a moving boundary frame using an ALE approach and considering Stefan flow. It provided the necessary information to understand the droplet to particle transformation steps in regions where in-flight probing was unfeasible, i.e. torch zone.

Ferritic stainless steels are the most commonly used materials for solid oxide fuel cell interconnect application. Although these alloys may meet the criteria for interconnect application for short periods of service, their application is limited for long-term use (i.e., 40,000 h) due to poor oxidation behaviour that results in a rapid increase in contact resistance. In addition, volatile Cr species migrating from the chromia scale can poison the cathode resulting in a considerable drop in performance of the cell. Coatings and surface modifications have been developed in order to mitigate the abovementioned problems. In this study, composite electrodeposition of reactive element containing particles in a metal matrix was considered as a solution to the interconnect problems. Nickel and Co were used as the metal matrix and LaCrO3 particles as the reactive element containing particles. The role of the particles was to improve the oxidation resistance and oxide scale adhesion, while the role of Ni or Co was to provide a matrix for embedding of the particles. Also, oxidation of the Ni or Co matrix led to the formation of conductive oxides. Moreover, as another part of this study, the effect of substrate composition on performance of steel interconnects was investigated. Numerous experimental techniques were used to study and characterise the oxidation behaviour of the composite coatings, as well as the metal-oxide scale interface properties. Scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDX), as well as surface analysis techniques including Auger electron spectroscopy (AES), X-ray photoelectron spectroscopy (XPS) and secondary ion mass spectroscopy (SIMS), were used for the purpose of characterization. The substrate used for coating was AISI-SAE 430 stainless steel that is considered as a typical, formerly used interconnect material. Also, for the purpose of the metal-oxide scale interfacial study, ZMG232 stainless steel that is a specially designed interconnect alloy was used. It is shown that the composite coatings greatly reduce the contact resistance and effectively inhibit Cr outward migration. In addition, it was determined that the presence of impurities in the steel, especially Si, and the absence of reactive elements drastically contribute to interconnect degradation. / Materials Science and Engineering