Solid oxide fuel cell with Ni–Al support

•We propose a new Ni–Al alloy for metal-supported SOFC.•Ni–Al substrates are appropriate for NiO/YSZ anode layers sintering in Ar.•NiO reduction during anode sintering leads to inhomogeneity of anode structure.•Magnetron sputtering was used for YSZ electrolyte deposition.•A 375 mW cm−2 maximum power density was achieved at 800 °C.

Metal-supported solid oxide fuel cells are considered as next generation of fuel cells. In this configuration, the use of metal support allows lowering the cost of fuel cell fabrication and provides enhanced durability. The paper presents the results concerning the manufacture and research of metal-supported solid oxide fuel cells with YSZ (yttria-stabilized zirconia) electrolyte. As a metal support the porous Ni–Al plates manufactured by combustion synthesis were used. The effects of synthesis conditions and composition of the Ni–Al samples on their properties were investigated. Solid oxide fuel cells with the structure of Ni–YSZ anode/YSZ electrolyte/LSCF cathode were fabricated by the combination of screen printing, magnetron sputtering, and electron beam treatment. The cell performance was analyzed by current–voltage measurements during operation at 700, 750, 800 and 850 °C. The obtained results are very promising at such an early stage of research for the future development of this technology.