Ni-YSZ self-supported films by gel electrophoresis

The manufacturing of metal-ceramic self-supported films by a colloidal process for fuel cell applications is reported. Ni and Ni-YSZ (with 30 vol.% YSZ) self-supported films have been prepared by combining electrophoretic deposition in water suspensions with thermogelling properties of carrageenan. Deposition is carried out on graphite electrodes which are removed on heating. The effect of the suspension solids loading and the concentration of gelling binder on the suspension rheology and electrophoretic deposition (EPD) performance are studied, as well as the deposition kinetics to optimize the deposit formation. Formed deposits are treated in air at 800 °C for graphite burning out and further sintered in reducing N2/10% H2 atmosphere at temperatures ranging from 1100 to 1400 °C. Porous films with homogeneous distribution of phases are obtained.