Integration of Ni-GDC layer on a NiCrAl metal foam for SOFC application

Metal supported Solid Oxide Fuel Cells (MS-SOFCs) have attracted considerable interest for their increased robustness and tolerance to redox and thermal cycling and their cheaper production costs. One of the main issue for the development of the MS-SOFC is the integration of the metallic-ceramic electrode onto a metal substrate using cheaper and easily scalable manufacturing techniques. In this study, the integration of a Ni-GDC anode layer on NiCrAl metal support with a porosity higher than 80 vol.% by conventional technique was successfully addressed. A defect free electrode of 5 × 5 cm2 of dimensions with smoothed surface (necessary for the electrolyte deposition) was obtained through a careful design of the thickness and the composition of the Ni-GDC layers and using (first time for this application) the stencil printing approach. The roughness of the final electrodic layer was comparable to the ones reported for layer deposited on flat/less porous ceramic substrates.