Electrophoretic deposition of functionally-graded NiO–YSZ composite films

Functionally-graded NiO–8 mol % YSZ composite films were prepared by a controlled voltage-decay electophoretic deposition (EPD) process. The films consisted of three layers with varying NiO concentrations and porosities. Effects of different parameters including the type of the organic media, solid concentration, NiO:YSZ ratio, and iodine on the stability of EPD suspensions and deposition kinetics were studied. A stable NiO–YSZ suspension was attained in isopropanol with NiO–YSZ ratio of 60:40 and iodine concentration of 0.5 mM. The composite film contained varying NiO concentration from 46 wt.% near the substrate to 32 wt.% close to the electrolyte with 42 wt% NiO in the intermediate region. The thickness of each layer is about 10, 44 and 68 μm, respectively. The prepared anode could be promising for solid oxide full cells as it compromises good contact to the electrode with higher corrosion resistance and active reaction zone with the electrolyte.