Fabrication of metal-supported solid oxide fuel cells by combining aerosol deposition and magnetron sputtering techniques.

In the present study, the fabrication route, including combining the aerosol deposition method and magnetron sputtering, was demonstrated for the fabrication of metal-supported solid oxide fuel cells. Thick-film anode layers (approximately 45 µm) of 10 mol.% gadolinia-doped ceria (GDC) and nickel (57/43 wt% ratio) were deposited by means of the aerosol deposition method on porous metal (Cr-28 wt%, Fe) supports from softly agglomerated submicron powders. The half-cells with the anode layers were sintered at 1000 °C in vacuum. Thin-film membranes of gadolinia-doped ceria (approximately 4 µm) were deposited by magnetron sputtering. (La0.80Sr0.20)0.95CoO3−δ (LSC) cathode layers were applied by screen printing with subsequent in situ sintering. The manufactured cells were investigated by scanning electron microscopy and electrochemical measurements. Depending on the manufacturing route and testing temperature, the cells with hydrogen as a fuel and air as an oxidant demonstrated open circuit voltages from 0.57 to 0.82 V. At 750 °C, the cell maximum power density was 0.3 W cm−2. [ABSTRACT FROM AUTHOR]