Quantification of double-layer Ni/YSZ fuel cell anodes from focused ion beam tomography data

• A new algorithm for the distinction between Ni-, YSZ-, and pore-phase is presented.
• 2 types of Ni/YSZ anodes are reconstructed and compared to each other.
• Microstructure parameters and particle size distributions are evaluated and discussed.
• The anode functional layer (AFL) adjacent to the electrolyte is separately quantified for the first time.
• Differences between both anode types and between AFL and substrates are discussed.

Three-dimensional microstructure reconstructions of Ni–yttria-stabilized zirconia (Ni/YSZ) anodes are presented, all of which are based on focused ion beam tomography data.The reconstruction procedure, starting from a series of 2D scanning electron micrographs, is investigated step by step and potential sources of error are identified. The distinction between Ni phase, YSZ phase and pore phase is solved by an advanced algorithm, which belongs to the region-growing image segmentation methods. This improves the accuracy of automated grayscale segmentation especially for images with low contrast, which is characteristic of both solid phases in Ni/YSZ anodes.Critical microstructure parameters like material fractions, surface areas, particle size and distribution of Ni, YSZ, and pore phase, as well as phase connectivity and triple-phase boundary density, are evaluated and discussed.In this contribution, two types of high-performance Ni/YSZ anodes – differing in thickness of both the anode functional layer and the anode substrate – are reconstructed and compared to each other. For the first time, the anode functional layer adjacent to the thin film electrolyte is separately quantified. The presented methods are qualified to quantitatively compare different anode microstructures and relate the result to their electrochemical performance.