Co-sintering anode and Y2O3 stabilized ZrO2 thin electrolyte film for solid oxide fuel cell fabricated by co-tape casting

Fabricating a large-area unit cell is very important for the development of solid oxide fuel cell (SOFC) stack. In this study, details of sintering process of half cell with NiO-yttria stabilized zirconia (YSZ) anode-supported YSZ thin electrolyte film fabricated by co-tape casting have been discussed. The results demonstrates that the shrinkages and shrinking rates mismatches between the electrolyte and the anode can be controlled by the organic additive content in the anode slurry composition and heating rate. Low heating rate suppresses the cracks formation in the electrolyte films. A warp-free unit cell with size of 100 × 100 mm2 and dense electrolyte has been successfully fabricated. A power of 22.2 W, with a power density of 0.27 W cm−2 has been achieved at 0.7 V and 750 °C in O2/humidified H2 atmosphere. The area specific resistance of the cell is 1.20 Ω cm2 at 0.7 V and 750 °C.

► The decomposition of the organic additive was discussed in details.
► The shrinkages mismatches can be controlled by heating rate and slurry compositions.
► A warp-free large-area unit cell has been successfully fabricated.
► The power of a 100 × 100 mm2 unit cell is 22.2 W at 0.7 V and 750 °C.