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Abstract In this study, EAVD(Electrostatic Assisted Vapor Deposition) technique was used to fabricate NiO/CGO (Cerium Gadolinum Oxide) films for the anode of IT-SOFCs (Intermediate Temperature-Solid Oxide Fuel Cells). The objective of this work is to establish the relationship between the morphology of NiO/CGO films and deposition parameters. The effects of different deposition parameters on film morphology were studied. The systematically changed deposition parameters were : deposition temperature, deposition time, flow rate and concentration of precursor solution and substrate types. According to experiment results, deposition temperature and deposition time are most important deposition parameters of controlling the morphology of films. The deposited NiO/CGO films with a highly porous structure were obtained above 400 oC and 5mins. On the other hand, when deposition temperature and time were decreased below 400 oC and 5mns, dense films were obtained. In this study, the flow rate and concentration of precursor solution and substrate types also influence the morphology of films, although to a lesser degree. The most suitable range of the flow rate is 0.7 cc/hr to 1.4 cc/hr. The XRD results show that the crystalline NiO/CGO film were obtained by EAVD technique.

The mathematical analysis has been developed by using finite volume method, experimental data from literatures, and solving numerically to predict solid oxide fuel cell performances with different operating conditions and different material properties. The in-house program presents flow fields, temperature distributions, and performance predictions of typical solid oxide fuel cells operating at different temperatures, 1000 C, 800 C, 600 C, and 500 C, and different electrolyte materials, Yttria-Stabilized zirconia (YSZ) and Gadolinia-doped ceria (CGO). From performance predictions show that the performance of an anode-supported planar SOFC is better than that of an electrolyte-supported planar SOFC for the same material used, same electrode electrochemical considerations, and same operating conditions. The anode-supported solid oxide fuel cells can be used to give the high power density in the higher current density range than the electrolyte-supported solid oxide fuel cells. Even though the electrolyte-supported solid oxide fuel cells give the lower power density and can operate in the lower current density range but they can be used as a small power generator which is portable and provide low power. Furthermore, it is shown that the effect of the electrolyte materials plays important roles to the performance predictions. This should be noted that performance comparisons are obtained by using the same electrode materials. The YSZ-electrolyte solid oxide fuel cells in this work show higher performance than the CGO-electrolyte solid oxide fuel cells when SOFCs operate above 756 C. On the other hand, when CGO based SOFCs operate under 756 C, they shows higher performance than YSZ based SOFCs because the conductivity values of CGO are higher than that of YSZ temperatures lower than 756 C. Since the CGO conductivity in this work is high and the effects of different electrode materials, they can be implied that conductivity values of electrolyte and electrode materials have to be improved.

Solid oxide fuel cells (SOFCs) are solid-state ceramic cells, typically operating between 1073 K and 1273 K. Because of high operating temperature, SOFCs are mostly applicable in stationary power generation. Among various configurations in which SOFCs exist, the planar configuration of solid oxide fuel cell (SOFC) has the potential to offer high power density due to shorter current path. Moreover, the planar configuration of SOFC is simple to stack and closely resemble the stacking arrangement of polymer electrolyte membrane (PEM) fuel cells. However, due to high operating temperature, there are problems associated with the development and commercialization of planar SOFCs, such as requirement of high temperature gas seals, internal stresses in cell components, and high material and manufacturing costs. Mathematical modeling is an essential tool for the advancement of SOFC technology. Mathematical models can help in gaining insights on the processes occurring inside the fuel cell, and can also aid in the design and optimization of fuel cells by examining the effect of various operating and design conditions on performance. A multi-component and multi-dimensional mathematical model of SOFCs has been developed in this thesis research. One of the novelties of the present model is its treatment of electrodes. An electrode in the present model is treated as two distinct layers referred to as the backing layer and the reaction zone layer. Reaction zone layers are thin layers in the vicinity of the electrolyte layer where electrochemical reactions occur to produce oxide ions, electrons and water vapor. The other important feature of the present model is its flexibility in fuel choice, which implies not only pure hydrogen but also any reformate composition can be used as a fuel. The modified Stefan-Maxwell equations incorporating Knudsen diffusion are used to model multi-component diffusion in the porous backing and reaction zone layers. The coupled governing equations of species, charge and energy along with the constitutive equations in different layers of the cell are solved for numerical solution using the finite volume method and developed code written in the computer language of C++. In addition, the developed numerical model is validated with various experimental data sets published in the open literature. Moreover, it is verified that the electrode in an SOFC can be treated as two distinct layers referred to as the backing layer and the reaction zone layer. The numerical model not only predicts SOFC performance at different operating and design conditions but also provides insight on the phenomena occurring within the fuel cell. In an anode-supported SOFC, the ohmic overpotential is the single largest contributor to the cell potential loss. Also, the cathode and electrolyte overpotentials are not negligible even though their thicknesses are negligible relative to the anode thickness. Moreover, methane reforming and water-gas shift reactions aid in significantly reducing the anode concentration overpotential in the thick anode of an anode-supported SOFC. A worthwhile comparison of performance between anode-supported and self-supported SOFCs reveals that anode-supported design of SOFCs is the potential design for operating at reduced temperatures. A parametric study has also been carried out to investigate the effect of various key operating and design parameters on the performance of an anode-supported SOFC. Reducing the operating temperature below 1073 K results in a significant drop in the performance of an anode-supported SOFC; hence ionic conductivity of the ion-conducting particles in the reaction zone layers and electrolyte needs to be enhanced to operate anode-supported SOFCs below 1073 K. Further, increasing the anode reaction zone layer beyond certain thickness has no significant effect on the performance of an anode-supported SOFC. Moreover, there is a spatial limitation to the transport of oxide ions in the reaction zone layer, thereby reflecting the influence of reaction zone thickness on cell performance.

Solid oxide fuel cells (SOFCs) are solid-state ceramic cells, typically operating between 1073 K and 1273 K. Because of high operating temperature, SOFCs are mostly applicable in stationary power generation. Among various configurations in which SOFCs exist, the planar configuration of solid oxide fuel cell (SOFC) has the potential to offer high power density due to shorter current path. Moreover, the planar configuration of SOFC is simple to stack and closely resemble the stacking arrangement of polymer electrolyte membrane (PEM) fuel cells. However, due to high operating temperature, there are problems associated with the development and commercialization of planar SOFCs, such as requirement of high temperature gas seals, internal stresses in cell components, and high material and manufacturing costs. Mathematical modeling is an essential tool for the advancement of SOFC technology. Mathematical models can help in gaining insights on the processes occurring inside the fuel cell, and can also aid in the design and optimization of fuel cells by examining the effect of various operating and design conditions on performance. A multi-component and multi-dimensional mathematical model of SOFCs has been developed in this thesis research. One of the novelties of the present model is its treatment of electrodes. An electrode in the present model is treated as two distinct layers referred to as the backing layer and the reaction zone layer. Reaction zone layers are thin layers in the vicinity of the electrolyte layer where electrochemical reactions occur to produce oxide ions, electrons and water vapor. The other important feature of the present model is its flexibility in fuel choice, which implies not only pure hydrogen but also any reformate composition can be used as a fuel. The modified Stefan-Maxwell equations incorporating Knudsen diffusion are used to model multi-component diffusion in the porous backing and reaction zone layers. The coupled governing equations of species, charge and energy along with the constitutive equations in different layers of the cell are solved for numerical solution using the finite volume method and developed code written in the computer language of C++. In addition, the developed numerical model is validated with various experimental data sets published in the open literature. Moreover, it is verified that the electrode in an SOFC can be treated as two distinct layers referred to as the backing layer and the reaction zone layer. The numerical model not only predicts SOFC performance at different operating and design conditions but also provides insight on the phenomena occurring within the fuel cell. In an anode-supported SOFC, the ohmic overpotential is the single largest contributor to the cell potential loss. Also, the cathode and electrolyte overpotentials are not negligible even though their thicknesses are negligible relative to the anode thickness. Moreover, methane reforming and water-gas shift reactions aid in significantly reducing the anode concentration overpotential in the thick anode of an anode-supported SOFC. A worthwhile comparison of performance between anode-supported and self-supported SOFCs reveals that anode-supported design of SOFCs is the potential design for operating at reduced temperatures. A parametric study has also been carried out to investigate the effect of various key operating and design parameters on the performance of an anode-supported SOFC. Reducing the operating temperature below 1073 K results in a significant drop in the performance of an anode-supported SOFC; hence ionic conductivity of the ion-conducting particles in the reaction zone layers and electrolyte needs to be enhanced to operate anode-supported SOFCs below 1073 K. Further, increasing the anode reaction zone layer beyond certain thickness has no significant effect on the performance of an anode-supported SOFC. Moreover, there is a spatial limitation to the transport of oxide ions in the reaction zone layer, thereby reflecting the influence of reaction zone thickness on cell performance.

Solid oxide fuel cell (SOFC) research is currently underway to improve performance, cost and durability by lowering the operating temperature to ~600°C. One approach is to design fabrication processes capable of tailoring desirable cathode microstructures to enhance mass and charge transfer properties through the porous medium. The aim of this study is to develop a cost effective fabrication technique for deposition of novel microstructures, specifically, functionally graded thin films of LSM oxide with porosity graded structure for use as IT- SOFCs cathode. Spray pyrolysis method was chosen as a low-temperature processing technique for deposition of porous LSM films onto dense YSZ substrates. The effort was directed toward the optimization of the processing conditions for deposition of high quality LSM films with variety of morphologies in the range of dense to porous microstructures. Results of optimization studies on spray parameters revealed that the substrate surface temperature is the most critical parameter influencing the roughness and morphology, porosity, cracking and crystallinity of the film. Physical and chemical properties of deposited thin films such as porosity, morphology, phase crystallinity and compositional homogeneity have shown to be extensively dependent on the deposition temperature as well as solution flow rate and the type of precursor solution among other parameters. The LSM film prepared from organo-metallic precursor and organic solvent showed a homogeneous crack-free microstructure before and after heat treatment as opposed to aqueous solution. Also, increasing the deposition temperature and the solution flow rate, in the specific range of 520-580 ℃ and 0.73-1.58 ml/min, respectively, leads to change the microstructure from a dense to a highly porous film. Taking the advantage of simplicity of spray pyrolysis technique combined with using metal-organic compounds, the conventional ultrasonic spray system was modified to a novel system whereby highly crystalline multi-layered porosity graded LSM cathode with columnar morphology and good electrical conductivity in the range of 500-700 °C was fabricated through a multi-step spray and via applying optimum combination of spray parameters. This achievement for the current graded LSM cathode would allow its use in IT-SOFCs.

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Conventional oxygen anion conducting yttria-stabilized zirconia (YSZ) based solid oxide fuel cells (SOFCs) operate at high temperatures (800oC-1000oC). SOFCs based on proton conducting ceramics, however, can operate at intermediate temperatures (450oC-750oC) due to low activation energy for protonic defect transport when compared to oxygen vacancy transport. Fuel cells that operate at intermediate temperatures ease the critical materials requirements of cell components and reduce system costs, which is necessary for large scale commercialization. BaCeO3-based perovskite materials are candidates for use as ion conductors in intermediate temperature SOFCs (IT-SOFCs) when doped with trivalent cations in the B-site. B-site doping forms oxygen vacancies which greatly increases the electrical conductivity of the material. The oxygen vacancies are consumed during the creation of protonic defects or electronic defects, depending on the atmosphere and temperature range. High performance IT-SOFCs based on the Y3+ and Yb3+ doped BaCeO3-based system, BaZr0.1Ce0.7Y0.1Yb0.1O3-δ (BZCYYb) have been recently reported. High conductivity in O2/H2O atmosphere was reported, however, a more basic understanding of the BZCYYb structure, electrical conductivity, and the portion of the charge carried by each charge carrier under fuel cell conditions is lacking. In this work, the BZCYYb material is fabricated by the solid state reaction method and the crystal structure at intermediate temperatures is studied using HT-XRD. The total conductivity of BZCYYb in H2/H2O, O2/H2O, and air atmospheres in the IT-SOFC temperature range is reported. The activation energy for transport at these conditions is determined from the conductivity data and the transference numbers of protonic defects, oxygen anion defects and electronic defects in the BZCYYb material are determined by the concentration cell - OCV method. BZCYYb is a mixed proton, oxygen anion, and electronic conductor at IT-SOFC temperature ranges (450oC - 750oC), in H2, O2, and H2O containing atmospheres. Ni-BZCYYb/BZCYYb/BZCYYb-LSCF fuel cells were constructed and peak power densities of ~1.2 W/cm2 were reported at 750oC after optimization of the Ni-BZCYYb anode porosity. Decreasing the Ni-BZCYYb anode porosity did not significantly affect the electrical conductivity of the anode, however the peak power densities of the IT-SOFCs based on the anode with less porosity, calculated from I-V curve data, showed dramatic improvement. The fuel cell with the lowest anode porosity demonstrated the highest performance. This finding is in stark contrast to the optimal anode porosity needed for high performance in YSZ-based, oxygen anion conducting SOFCs. Because of significant proton conduction in the BZCYYb material, fuel cell reaction products (water) form at the cathode side and less porosity is required on the anode side. The improvement in performance in the BZCYYb based IT-SOFC is attributed to the unique microstructure formed in the Ni-BZCYYb anode when no pore forming additives are used which may contribute to high electrocatalytic behavior for anode reactions. This work provides a basic understanding of the electrical properties of BZCYYb and clarifies the feasibility of using BZCYYb in each component of the IT-SOFC system as well as in other electrochemical devices. The high performance of the Ni-BZCYYb/BZCYYb/BZCYYb-LSCF IT-SOFC, due to low anode porosity, provides a new understanding for the rational development of high performance IT-SOFCs based on electrolytes with significant protonic conduction.

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