Low-temperature preparation of dense (Gd,Ce)O2−δ–Gd2O3 composite buffer layer by aerosol deposition for YSZ electrolyte-based SOFC

The (Gd0.1Ce0.9)O2−δ (GDC)–Gd2O3 composite buffer layer was fabricated on yttria stabilized zirconia (YSZ) electrolyte by aerosol deposition for usage as diffusion barrier layer between YSZ and (La0.6Sr0.4)(Co0.2Fe0.8)O3−δ (LSCF)–GDC composite cathode. The deposited composite buffer layer was quite dense in nature and effectively prevented the formation of SrZrO3 and La2Zr2O7 interlayer with low conductivity at the interfaces. The cell's I–V performance was enhanced with an increase in the GDC content in the composite buffer layer. The cell containing composite buffer layer showed maximum power density of up to 1.74 W/cm2 at 750 °C, which was ∼30% higher than that of the cell containing GDC buffer layer prepared using conventional process.

► We fabricated GDC composite buffer layer at room temperature by aerosol deposition.
► The deposited buffer layer effectively prevented unfavorable interlayer formation.
► I–V performance was enhanced with an increase in the GDC content in the buffer layer.
► The developed composite buffer layer has been applied to large SOFCs and stacks.