Ink-Jet Printing: A Versatile Method for Multilayer Solid Oxide Fuel Cells Fabrication

The potential of ink-jet printing for fabrication of components for solid oxide fuel cells has been explored. An anode interlayer, consisting of a composite of NiO and yttria-stabilized zirconia (YSZ), and an electrolyte layer, YSZ (8 mol%), were ink-jet printed on a tape cast anode support, 55 wt% NiO-45 wt% YSZ (8 mol%). Scanning electron microscopy of the printed layers sintered at 1400 degrees C revealed a dense electrolyte layer measuring 10-12 mu m in thickness. Single cells using these printed layers and strontium-doped lanthanum manganate (LSM, La0.8Sr0.2MnO3)-based pasted cathodes were assessed by DC polarization and AC complex impedance methods. The cells exhibited a stable open circuit voltage of 1.1 V around 800 degrees C, in a hydrogen atmosphere. A maximum power density of 500 m center dot(W center dot cm)-2 was achieved at 850 degrees C for a typical cell with the electrolyte and anode interlayer cosintered at 1400 degrees C. A composite cathode interlayer, LSM-YSZ, and a cathode current collection layer, LSM, were also ink-jet printed and incorporated in single cells. However, cells with all components ink-jet printed showed decreased performance. This pointed to critical issues in the composite cathode microstructure, which is controlled by the composite ink design/formulation and printing parameters that need to be addressed.