Fabrication of metal-supported tubular solid oxide fuel cell by phase-inversion method and in situ reduction

•Metal-supported tubular SOFCs were successfully fabricated by in situ reduction.•Supports with sponge-like pores were prepared through phase-inversion method.•Crack-free electrolyte film was achieved without pre-firing the support.

Ni–Fe alloy supported tubular solid oxide fuel cells (SOFCs) were successfully fabricated by a low cost and simple process involving phase-inversion, co-sintering and in situ reduction. The tubular metal supports have a special structure consisting of uniformly distributed sponge-like pores. It has proven that co-sintering the as-prepared tubular supports together with half cells (anode and electrolyte layers) is in favor of obtaining the YSZ crack-free electrolyte film. In addition to the support for SOFC, the Ni–Fe alloy tube also serves as current collector at the anode side after fully in situ reduction. The maximum power densities of the Ni–Fe alloy supported tubular SOFCs are 0.26 W cm−2 at 800 °C, using moist hydrogen as fuel and ambient air as oxidant. The present work demonstrates the feasibility for the fabrication of metal-supported SOFCs with acceptable performance using economical techniques.