Fabrication and evaluation of solid-oxide fuel cell anodes employing reaction-sintered yttria-stabilized zirconia

This paper reports on the fabrication and performance of solid-oxide fuel cell (SOFC) anodes utilizing yttria reaction-sintered zirconia (YRSZ). Through the reaction-sintering process, the technical-grade YSZ commonly used in the Ni–YSZ anode cermet is replaced with lower-cost ZrO2 and Y2O3 materials. When sintered in the presence of nickel oxide, ZrO2 and Y2O3 form cubic-phase YSZ at temperatures characteristic of SOFC processing (1400–1550 °°C). Reaction sintering enables the formation of YSZ during cell fabrication, reducing SOFC anode raw-materials cost and the number of SOFC-fabrication processes. This paper reports the results of a broad range of characterization and performance measurements to evaluate the YRSZ material, including (1) crystal structure, (2) morphology, (3) pore-size distribution, (4) electronic resistivity, (5) fracture strength, (6) gas transport and catalytic activity, and (7) electrochemical performance. Material properties and performance are found to be comparable to or better than equivalent materials fabricated by conventional processes.