| Research was performed on the development of metal-supported solid oxide fuel cell (SOFC) electrolytes by suspension and solution precursor plasma spraying (SPS and SPPS). Experiments were conducted to understand the effects of many plasma-, feedstock-, and substrate-related process parameters on the microstructure, permeability, and conductivity of the resulting coatings. Most work was performed with yttria-stabilized zirconia (YSZ), but samaria-doped ceria (SDC) was also considered.;The plasma-to-substrate heat flux behaviour of the process is particularly relevant for producing dense electrolytes with low segmentation cracking. Heat flux profiles for various processing conditions were experimentally determined and then used to model temperature distributions in the electrolyte and substrate during deposition. The results showed a strong correlation between segmentation crack severity and the peak temperature difference between the electrolyte surface and the metal support during deposition.;Building on these findings, two strategies were developed for improving electrolyte performance. The first strategy is to use a bi-layer electrolyte structure, in which one layer is dense but has segmentation cracks and the other layer is more porous but contains relatively few segmentation cracks. A cell with a bi-layer electrolyte achieved a peak power density of 0.718 W cm-2 at 750 °C using hydrogen as fuel.;The second strategy involves reducing the thickness and roughness of the electrode on which the electrolyte is deposited, which first required the development of improved metal supports. A thinner electrode reduces the thermal stresses that drive segmentation cracking and a smoother surface minimizes the formation of concentrated porosity. A cell with a 16 mum thick anode and a 21 mum thick electrolyte achieved an open circuit voltage (OCV) of 1.053 V, a series resistance of 0.284 O cm2, and a peak power density of 0.548 W cm-2 at 750 °C using hydrogen as fuel. A separate cell with a 28 mum thick electrolyte achieved an OCV of 1.068 V. At the end of the thesis, cell performance is compared to that of state-of-the-art cells produced in other facilities and using other production methods. |
