Fabrication of thin film solid oxide fuel cells

In this research pressurized gas atomization spray pyrolysis deposition was used to make Ce0.9Gd0.1O1.95-x and BaCe 0.8Y0.2O3-alpha (BCY) films <5 mum thick on anode substrates. The purpose was to test the efficacy of BCY as a protective layer for CGO in SOFCs. Cells were produced with CGO, BCY or BCY + CGO bi-layer configurations and the electrical properties were tested to determine performance differences with the use of a bi-layer electrolyte.;Optimization of the spray process was undertaken with special attention paid to the effects of substrate roughness and porosity on film development. It was found that substrate roughness enhances wetting of an alcohol based spray solution on anode substrates. Enhanced wetting is good for film formation during aerosol spray deposition, but substrate porosity will transport solution from the surface before complete surface coverage is achieved. Continued deposition is required to achieve complete coverage.;Cells with CGO electrolytes produced open circuit voltages (0.74 V) and power output at 600°C (23 mW/cm2), comparable to literature values for cells tested with 5% H2 in argon fuel. Cells with BCY electrolytes displayed a lower open circuit voltage (0.8 V) than expected but may be an effective protective layer as the bi-layer cells also produced similar voltages (0.8 V).