The influence of the reducing conditions on the final microstructure and performance of nickel-yttria stabilized zirconia cermets

Ni-YSZ (yttria stabilized zirconia) cermets are the most widespread composite materials to be used as SOFC fuel electrodes. These materials are generally fabricated by the reduction of NiO to Ni in a NiO-YSZ composite, where the reducing conditions have a great effect in the final microstructure of the electrode. In the present work, several reducing conditions were explored in order to find the most suitable microstructure for anode-supported microtubular solid oxide fuel cells (SOFCs). Samples were firstly reduced in either pure or diluted H2 (dry or humidified), at temperatures ranging from 400 to 800 °C while their DC conductivity was monitored. The highest conductivity value was measured for the sample reduced in pure humidified hydrogen at 800 °C. However, this sample experienced conductivity degradation in comparison with samples reduced under dry conditions. For the studied temperature range, nucleation of nano-porous nickel particles is firstly formed during reduction. However, from our experiments it was concluded that those nanoparticles are not stable with time, at least at temperatures between 600 °C and 800 °C. Electrochemical characterization of complete microtubular cells under real wet conditions was also performed under current load, confirming that the microstructure of the Ni-YSZ cermet is still evolving during operation.