Mechanical reliability and durability of SOFC stacks. Part I : Modelling of the effect of operating conditions and design alternatives on the reliability

Electrochemical and mechanical aspects in solid oxide fuel cell stack must be understood to meet the reliability targets for market implementation. This study presents a stack modelling framework that combines thermo-electrochemical models, including degradation and a contact finite-element thermo-mechanical model. It considers rate-independent plasticity and creep of the component materials and proposes periodic boundary conditions to model the stacking of repeating units. This Part I focuses on the effects of the operating conditions and design alternatives.In the present conditions, the stresses in both the anode and the cathode contribute to the probability of failure (PfPf), which can be lowered by adjusting the operating conditions. The requirements for mechanical reliability are here opposite to those that alleviate electrochemical degradation. Gas-diffusion layers (GDL) and interconnect design alternatives and stacking have a lower impact on the PfPf, but affect the contact pressure on the GDLs, which can cause electrical contacting challenges.

► We analyse together electrochemical degradation and mechanical reliability.
► Trade-offs between electrochemical performance and mechanical reliability.
► Effects of operating conditions on mechanical failures.
► Effect of design alternatives on cell/sealant/contact failure and stack deformation.