High-performance ultra-thin film solid oxide fuel cell using anodized-aluminum-oxide supporting structure

•Ultra-thin membrane-electrode assembly fabrication•Hybrid platinum electrode deposition scheme•Atomic layer deposition of yttria-stabilized zirconia without pinhole defects•High-performance anode supported LT-SOFC

An ultra-thin-film, low-temperature, high performing solid-oxide fuel cell (LT-SOFC) was successfully fabricated on an anodized aluminum oxide (AAO) supporting structure via atomic layer deposition (ALD). A dense and pinhole free layer of hybrid platinum (Pt) was applied to reduce the size of the substrate pores, in order to facilitate the development of a dense electrolyte on the Pt electrode while maintaining the gaseous fuel access. As a result, about 180 nm-thick yttria-stabilized zirconia (YSZ) electrolyte was successfully deposited without pinholes. This ultra-thin-film, AAO-supported LT-SOFC demonstrates the highest performance with a maximum power density of 380 mW/cm2 at an operating temperature of 450 °C.