Research was performed on the development of relationships between the microstructure of nickel and yttria-stabilized zirconia (YSZ) coatings and the processing parameters used for their deposition by atmospheric plasma spraying (APS). Research was also performed on the development of relationships between the microstructure of plasma sprayed Ni-YSZ coatings and the electrochemical performance of metal-supported solid oxide fuel cells (SOFCs) incorporating these coatings as anodes.
Three APS processes were used to deposit Ni-YSZ coatings: dry-powder plasma spraying (DPPS), suspension plasma spraying (SPS), and solution precursor plasma spraying (SPPS). These processes differ in the form of the feedstock injected into the plasma. The composition of the Ni-YSZ coatings deposited with each spray process could be controlled through adjustment of the plasma gas composition and stand-off distance, as well as adjustment of feedstock properties including agglomerate size fraction for DPPS, NiO particle size and suspension feed rate in SPS, and the enthalpy of decomposition of the precursors used in SPPS. The porosity of the Ni-YSZ coatings could be controlled through the addition of a sacrificial pore forming material to each feedstock, with coating porosities up to approximately 35% being achieved for each coating type.
Metal-supported SOFCs were fabricated to each have anodes deposited with a different plasma spray process, where all anodes had nominally identical composition. The microstructures obtained for each anode type were distinctly different. SPPS led to the most uniform mixing of the smallest Ni and YSZ particles. These anodes most resembled typical structures from anodes fabricated using conventional methods. It was found that the polarization resistance, Rp, associated with the high frequency (> 1 kHz) range of the impedance spectrum correlated to the three phase boundary length (TPBL) density of each anode, with lower Rp values corresponding to higher TPBL densities. It was also found that the Knudsen diffusion coefficient and effective ordinary diffusion coefficient of the porous anodes correlated with the Rp associated with the low frequency (< 1 kHz) range of the impedance spectrum. Therefore, the impedance spectrum can be used to compare microstructural differences among plasma sprayed Ni-YSZ anodes.
| Identifer | oai:union.ndltd.org:LACETR/oai:collectionscanada.gc.ca:OTU.1807/43667 |
| Date | 13 January 2014 |
| Creators | Metcalfe, Thomas Craig |
| Contributors | Kesler, Olivera |
| Source Sets | Library and Archives Canada ETDs Repository / Centre d'archives des thèses électroniques de Bibliothèque et Archives Canada |
| Language | en_ca |
| Detected Language | English |
| Type | Thesis |
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