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.

The feasibility of highly dispersed gold nanocatalyst supported on yttria-stabilized zirconia (YSZ) for the model reactions of C2H4 and CO oxidation is demonstrated for the first time. Gold nanoparticles are synthesized on YSZ powder by chemical reduction of the precursor salt in the mixture of ethanol, water and polyvinylpyrrolidone (PVP). Resulting metal loading of the catalysts are 1 wt.% with average particle sizes ranging from 6 to 9 nm. Results of CO and C2H4 oxidation display catalytic activity at 65 0C and 25 0C for CO and C2H4 oxidation, respectively. The catalytic properties of the catalysts are different due to their average particle size. Electrochemical Promotion of Catalysis (EPOC) of C2H4 oxidation is demonstrated. Application of constant potential difference between two electrodes in the bipolar electrochemical cell led to increase in C2H4 conversion. A proposed mechanism explains the bipolar EPOC phenomenon through formation of O2- flux across the electrochemical cell, resulting in the change of Work Function of gold nanoparticles placed in between the electrodes and is electronically isolated.

A solid oxide fuel cell (SOFC) is an energy conversion device that has the potential to efficiently generate electricity in an environmentally-friendly manner. In general, a SOFC operates between 750&deg;C and 1000&deg;C utilizing hydrogen or hydrocarbons as fuel and air as an oxidant. The three major components comprising a fuel cell are the electrolyte, the cathode, and the anode. At present, the state-of-the-art SOFC is made from a dense yttria-stabilized zirconia (YSZ) electrolyte, a porous lanthanum manganite cathode, and a porous nickel/YSZ composite anode. With the advent of the anode-supported SOFC and the increased interest in using a wider range of fuels, such as those containing sulphur, knowledge of the anode properties is becoming more important. <br /> The properties of the current anodes are limited due to the narrow range of nickel loadings imposed by the minimum nickel content for electrical conductivity and the maximum allowable nickel loading to avoid thermal mismatch with the YSZ electrolyte. In addition, there is little research presented in the literature regarding the use of nickel metal as a starting anode material, rather than the traditional nickel oxide powder, and how porosity may affect the anode properties. <br /> The purpose of this investigation is to determine the influence nickel morphology and porosity distribution have on the processing and properties of tape cast Ni/YSZ composites. Specifically, the sintering characteristics, electrical conductivity, and thermal expansion behaviour of tape cast composites created from YSZ, nickel, nickel oxide (NiO), nickel coated graphite (NiGr), and/or graphite (Gr) powders are investigated. In addition to samples made from 100% YSZ, 100% Ni, and 100% NiO powders, five composite types were created for this investigation: NiO/YSZ, NiO&Gr/YSZ, Ni/YSZ, NiGr/YSZ, and Ni&Gr/YSZ each with nickel loadings varying between 4 vol% Ni of total solids and 77 vol% Ni of total solids. Another set of composites with a fixed nickel loading of 27 vol% Ni and 47 vol% Ni of total solids and varying graphite loadings were also created. <br /> During the burnout stage, the composites made from nickel oxide powder shrink slightly while the composites made from nickel metal expand due to nickel oxidation. Graphite additions below 20 vol% of the green volume do not alter the dimensional changes of the composites during burnout, but graphite loadings greater than 25 vol% of the green volume cause significant expansion in the thickness of the composites. <br /> After sintering, the amount of volumetric sintering shrinkage decreases with higher nickel loadings and is greater for the composites made with nickel oxide compared to the composites made from nickel metal. The porosity generated in the composites containing graphite is slightly higher than the volume of graphite added to the composite and is much greater than the porosity contained in the graphite-free composites. <br /> Dimensional changes of the porous Ni/YSZ and NiO/YSZ composites during both burnout and sintering were analysed based on concepts of constrained sintering of composite powder mixtures. In some cases constrained sintering was evident, while in others, a more simple rule of mixtures behaviour for shrinkage as a function of YSZ content was observed. <br /> When nickel oxide is reduced to nickel metal during the reduction stage there is essentially no change in the composite volume for the composites containing YSZ because the YSZ prevents the composites from shrinking. After reduction the additional porosity generated in the composites is equivalent to the change in volume due to the reduction of nickel oxide to nickel metal. <br /> When measuring the electrical conductivity, each composite type demonstrated classic percolation behaviour. The NiGr/YSZ composites had the lowest percolation threshold, followed by the Ni/YSZ and NiO/YSZ composites. When graphite was added with a nickel coating, the added porosity did not disrupt the nickel percolation network and allowed the nickel to occupy a larger effective volume compared to a composite made with similar sized solid nickel particles. When graphite was added to the composites, the electrical conductivity was reduced and the percolation threshold increased. <br /> Generally, the coefficient of thermal expansion (CTE) for Ni/YSZ composites are expected to follow the rule of mixtures prediction since the elastic properties for nickel and YSZ are similar. However when porosity is distributed unevenly between the YSZ and nickel phases, the CTE prediction will deviate from the rule of mixtures. When cornstarch was added to the NiGr/YSZ composites, the CTE increased as the amount of porosity in the YSZ phase increased. The CTE of the NiGr/YSZ composites followed the rule of mixtures indicating that the porosity was evenly distributed between the nickel and YSZ phases. For the other composite types, the measured CTE was higher than the rule of mixtures prediction suggesting that more porosity was contained within the YSZ phase.

A solid oxide fuel cell (SOFC) is an energy conversion device that has the potential to efficiently generate electricity in an environmentally-friendly manner. In general, a SOFC operates between 750&deg;C and 1000&deg;C utilizing hydrogen or hydrocarbons as fuel and air as an oxidant. The three major components comprising a fuel cell are the electrolyte, the cathode, and the anode. At present, the state-of-the-art SOFC is made from a dense yttria-stabilized zirconia (YSZ) electrolyte, a porous lanthanum manganite cathode, and a porous nickel/YSZ composite anode. With the advent of the anode-supported SOFC and the increased interest in using a wider range of fuels, such as those containing sulphur, knowledge of the anode properties is becoming more important. <br /> The properties of the current anodes are limited due to the narrow range of nickel loadings imposed by the minimum nickel content for electrical conductivity and the maximum allowable nickel loading to avoid thermal mismatch with the YSZ electrolyte. In addition, there is little research presented in the literature regarding the use of nickel metal as a starting anode material, rather than the traditional nickel oxide powder, and how porosity may affect the anode properties. <br /> The purpose of this investigation is to determine the influence nickel morphology and porosity distribution have on the processing and properties of tape cast Ni/YSZ composites. Specifically, the sintering characteristics, electrical conductivity, and thermal expansion behaviour of tape cast composites created from YSZ, nickel, nickel oxide (NiO), nickel coated graphite (NiGr), and/or graphite (Gr) powders are investigated. In addition to samples made from 100% YSZ, 100% Ni, and 100% NiO powders, five composite types were created for this investigation: NiO/YSZ, NiO&Gr/YSZ, Ni/YSZ, NiGr/YSZ, and Ni&Gr/YSZ each with nickel loadings varying between 4 vol% Ni of total solids and 77 vol% Ni of total solids. Another set of composites with a fixed nickel loading of 27 vol% Ni and 47 vol% Ni of total solids and varying graphite loadings were also created. <br /> During the burnout stage, the composites made from nickel oxide powder shrink slightly while the composites made from nickel metal expand due to nickel oxidation. Graphite additions below 20 vol% of the green volume do not alter the dimensional changes of the composites during burnout, but graphite loadings greater than 25 vol% of the green volume cause significant expansion in the thickness of the composites. <br /> After sintering, the amount of volumetric sintering shrinkage decreases with higher nickel loadings and is greater for the composites made with nickel oxide compared to the composites made from nickel metal. The porosity generated in the composites containing graphite is slightly higher than the volume of graphite added to the composite and is much greater than the porosity contained in the graphite-free composites. <br /> Dimensional changes of the porous Ni/YSZ and NiO/YSZ composites during both burnout and sintering were analysed based on concepts of constrained sintering of composite powder mixtures. In some cases constrained sintering was evident, while in others, a more simple rule of mixtures behaviour for shrinkage as a function of YSZ content was observed. <br /> When nickel oxide is reduced to nickel metal during the reduction stage there is essentially no change in the composite volume for the composites containing YSZ because the YSZ prevents the composites from shrinking. After reduction the additional porosity generated in the composites is equivalent to the change in volume due to the reduction of nickel oxide to nickel metal. <br /> When measuring the electrical conductivity, each composite type demonstrated classic percolation behaviour. The NiGr/YSZ composites had the lowest percolation threshold, followed by the Ni/YSZ and NiO/YSZ composites. When graphite was added with a nickel coating, the added porosity did not disrupt the nickel percolation network and allowed the nickel to occupy a larger effective volume compared to a composite made with similar sized solid nickel particles. When graphite was added to the composites, the electrical conductivity was reduced and the percolation threshold increased. <br /> Generally, the coefficient of thermal expansion (CTE) for Ni/YSZ composites are expected to follow the rule of mixtures prediction since the elastic properties for nickel and YSZ are similar. However when porosity is distributed unevenly between the YSZ and nickel phases, the CTE prediction will deviate from the rule of mixtures. When cornstarch was added to the NiGr/YSZ composites, the CTE increased as the amount of porosity in the YSZ phase increased. The CTE of the NiGr/YSZ composites followed the rule of mixtures indicating that the porosity was evenly distributed between the nickel and YSZ phases. For the other composite types, the measured CTE was higher than the rule of mixtures prediction suggesting that more porosity was contained within the YSZ phase.

Solid oxide fuel cells are electrochemical energy conversion devices utilizing solid electrolytes transporting O2- that typically operate in the 800 - 1000 °C temperature range due to the large activation barrier for ionic transport. Reducing electrolyte thickness or increasing ionic conductivity can enable lower temperature operation for both stationary and portable applications. This thesis is focused on the fabrication of free standing ultrathin (<100 nm) oxide membranes of prototypical O2- conducting electrolytes, namely Y2O3-doped ZrO2 and Gd2O3-doped CeO2. Fabrication of such membranes requires an understanding of thin plate mechanics coupled with controllable thin film deposition processes. Integration of free standing membranes into proof-of-concept fuel cell devices necessitates ideal electrode assemblies as well as creative processing schemes to experimentally test devices in a high temperature dual environment chamber. We present a simple elastic model to determine stable buckling configurations for free standing oxide membranes. This guides the experimental methodology for Y2O3-doped ZrO2 film processing, which enables tunable internal stress in the films. Using these criteria, we fabricate robust Y2O3-doped ZrO2 membranes on Si and composite polymeric substrates by semiconductor and micro-machining processes, respectively. Fuel cell devices integrating these membranes with metallic electrodes are demonstrated to operate in the 300 - 500 °C range, exhibiting record performance at such temperatures. A model combining physical transport of electronic carriers in an insulating film and electrochemical aspects of transport is developed to determine the limits of performance enhancement expected via electrolyte thickness reduction. Free standing oxide heterostructures, i.e. electrolyte membrane and oxide electrodes, are demonstrated. Lastly, using Y2O3-doped ZrO2 and Gd2O3-doped CeO2, novel electrolyte fabrication schemes are explored to develop oxide alloys and nanoscale compositionally graded membranes that are thermomechanically robust and provide added interfacial functionality. The work in this thesis advances experimental state-of-the-art with respect to solid oxide fuel cell operation temperature, provides fundamental boundaries expected for ultrathin electrolytes, develops the ability to integrate highly dissimilar material (such as oxide-polymer) heterostructures, and introduces nanoscale compositionally graded electrolyte membranes that can lead to monolithic materials having multiple functionalities. / Engineering and Applied Sciences

Inorganic based membranes which have a symmetric/asymmetric structure have been produced using an immersion induced phase inversion and sintering method. An organic binder solution (dope) containing yttria-stabilised zirconium (YSZ) particles is spun through a triple orifice spinneret to form a hollow fibre precursor, which is then sintered at elevated temperatures to form a ceramic support. The phase inversion process for the formation of hollow fibre membranes was studied in order to produce the best morphological structure/support for palladium based membranes. The spinning parameters, particle size, non-solvent concentration, internal coagulant as well as the calcination temperature were investigated in order to determine the optimum values. Sintering temperature was also investigated, which would yield a sponge-like structure with an optimized permeability, while retaining a smooth outer surface. The supports produced by phase inversion were characterized in terms of dimension by mercury porosimetry, compressed air permeability, Surface Electron Microscopy (SEM) and Atomic Force Microscopy (AFM). The morphology of the produced ceramic support showed either dense or porous characteristics governed by the dynamics of the phase inversion process. The particle size of YSZ was examined in order to decrease the amount of agglomerates in the spinning suspension. Zetasizer tests indicated that at 15 minutes, the ultrasonic bath effectively homogenised the YSZ particles and prohibited soft agglomerates from reforming in the spinning suspension. In this study, an increase in air gap had no noticeable effect on the finger like voids but it had a considerable effect on both the inner diameter (ID) and outer diameter (OD) of the green fibres, while an increase in bore liquid flow rate and extrusion pressure promoted viscous fingering and significant effect on the ID and OD of the fibres, respectively. There was a decrease in porosity and permeability with increasing sintering temperature, addition of water concentration in the spinning suspension and varying Nmethylpyrrolidone (NMP) aqueous solution of the internal coagulant. The amount of YSZ added to the starting suspension influenced the properties of the support structure. Viscous deformation was observed for dope with lower particle loading thus resulted in the formation of cracks and defects during sintering. / >Magister Scientiae - MSc

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.

The feasibility of highly dispersed gold nanocatalyst supported on yttria-stabilized zirconia (YSZ) for the model reactions of C2H4 and CO oxidation is demonstrated for the first time. Gold nanoparticles are synthesized on YSZ powder by chemical reduction of the precursor salt in the mixture of ethanol, water and polyvinylpyrrolidone (PVP). Resulting metal loading of the catalysts are 1 wt.% with average particle sizes ranging from 6 to 9 nm. Results of CO and C2H4 oxidation display catalytic activity at 65 0C and 25 0C for CO and C2H4 oxidation, respectively. The catalytic properties of the catalysts are different due to their average particle size. Electrochemical Promotion of Catalysis (EPOC) of C2H4 oxidation is demonstrated. Application of constant potential difference between two electrodes in the bipolar electrochemical cell led to increase in C2H4 conversion. A proposed mechanism explains the bipolar EPOC phenomenon through formation of O2- flux across the electrochemical cell, resulting in the change of Work Function of gold nanoparticles placed in between the electrodes and is electronically isolated.

Electrophoretic deposition (EPD) has been used to produce the yttria-stabilized zirconia (YSZ) coatings on metal substrates. Sintering of YSZ with and without doping has been carried out at 1150 °C for 2hrs. The properties of these coatings have been examined in light of thermal barrier applications. For EPD, the green density increases with an initial increase in the HCl concentration and the EPD time. This suggests that particle packing was influenced by a time dependent re-arrangement, in addition to the initial suspension dispersion state. The green density peaks at a electrical conductivity of around 10×10-4 S/m achieved by an 0.5 mM HCl addition for the 20 g/l suspensions with the EPD time of around 8 ~10 minute. For sintered coatings, the HCl concentration had a marked effect on the neck size to grain size ratio of the 8 mol% yttria-stabilized zirconia (8YSZ) coatings. The presence of ZrCl4 and ZrOCl2, and a high concentration of oxygen vacancies at the grain boundaries are believed to promote neck growth in the early stage of sintering at 1150 °C. During sintering of 3 mol% and 8 mol% yttria-stabilized zirconia (3YSZ and 8YSZ) at 1150 ºC for 2hrs, the densification rate substantially increased with a small amount of Fe2O3 addition (0.5 mol%) to the 3YSZ/8YSZ deposits. A more pronounced graingrowth was present in the Fe2O3 doped 8YSZ deposits. The increased Zr4+ diffusion coefficient is mainly responsible to the rapid densification rate of the Fe2O3 doped 3YSZ/8YSZ deposits. A small grain growth observed in the Fe2O3 doped 3YSZ deposits is attributed to the Fe3+ segregation at grain boundary. A small amount of CeO2 doping was found to substantially inhibit the densification rate of the doped 3YSZ deposits with a minor grain growth. Fe2O3 doping reduced the thermal conductivities of 3YSZ/8YSZ. It is found that Rayleigh-type phonon scattering due to the mass difference alone is inadequate to explain the thermal conductivity of Fe2O3 doped YSZ systems. The lattice strain effects due to the ionic radius difference could more effectively reduce thermal conductivity of the Fe2O3-doped 3YSZ. A decrease in the growth rate of the TGO scale with the increasing Fe2O3 additions was observed for the oxidized FeCrAlY metal substrates with the Fe2O3-doped 3YSZ coating, which was found to be attributed to the early formation of the stable and dense α-Al2O3 phase due to the presence of Fe3+ ions.

The purpose of this thesis was to carry out the experimental study of direct ammonia fuel cells. The use of hydrogen in fuel cells poses a lot of problems. There is a lot of safety, technical and economic issues to be overcome to make its use as a fuel widespread. Ammonia is being considered as a very promising source of hydrogen for fuel cells. However, until now its use in fuel cells has received very little attention. Ammonia presents many advantages over hydrogen and other potential sources of hydrogen such as an easy storage and a world-wide distribution network. Ammonia is a suitable hydrogen carrier and can be easily cracked at high temperatures such as those used in solid oxide fuel cells. The present study was conducting using ammonia as fuel and argon as carrier gas in different solid oxide fuel cell systems: an annular design, a planar design and a micro laminated reactor. The electrolyte materials were calcia stabilized zirconia and yttria stabilized zirconia. As far as the electrodes are concerned, silver, platinum and nickel cermet were used as anode/materials and silver was employed as cathode material. The cell yoltage was measured as function of reactor configuration, space time, ammonia flow rate and ammonia concentration. The results demonstrate the high potential of ammonia over hydrogen when nickel is used as anode material. Solid proton conducting fuel cells operating on ammonia fuel were also studied. The electrolyte materials were fabricated from neodymium and gadolinium doped barium and strontium cerates. The dopant fraction ranged from 1 to 20 wt%. Silver was employed as cathode and anode material and was spray deposited. The application of proton conducting electrolytes results in higher current densities for a given voltage than the using typical oxide ion conductors such as 8mol % yttria stabilized zirconia. The potential of the proton conducting materials for application in ammonia synthesis at atmospheric pressure was also studied. They demonstrated promising results and could prove to be an alternative to the common ammonia synthesis processes.