Porous electrolyte-supported tubular micro-SOFC design

Due to the poor redox cycling resistance of the second generation of μ-SOFCs, a new generation of SOFC has been recently developed using a porous electrolyte-supported structure to overcome this problem. In this research, the porous structure was successfully fabricated with slip casting using calcined YSZ (ZrO2 + 8 mol% Y2O3) with or without graphite as a pore former. Calcination of YSZ powder at 1300–1500 °C prior to making the slip leads to growth of YSZ crystals and particle size which results in a decrease in surface area and powder sinterability. This was found to be an important criterion in developing the porous structure as, due to the high sinterability of non-calcined YSZ, even the addition of graphite is inadequate to generate sufficient open porosity. A dense YSZ electrolyte layer was immediately coated on the porous structure using YSZ calcined at 1300 °C with a sequential slip casting method. Sample thickness was found to be a function of both graphite content as well as YSZ calcination temperature. Physical properties of the porous YSZ supports and SEM analysis of the support and coated electrolyte are presented.