Characterization of laser-processed thin ceramic membranes for electrolyte-supported solid oxide fuel cells

By laser machining we have prepared thin and self-supported yttria stabilized zirconia (YSZ) electrolytes that can be used in electrolyte-supported solid oxide fuel cells for reducing the operation temperature. The membranes, which are supported by thicker areas of the same material, have an active area of ∼20 μm in thickness and up to 8 mm in diameter. Buckling limits the maximum size of the thin areas to below 1 mm, the overall effective active area being formed by multiple thin areas bounded by ribs. Electron Backscattering Diffraction experiments determined that there are not significant strains inside the membranes and that the heat-affected zone is confined to a shallow layer of ∼1–2 μm. The bending strength of the membranes decreases by ∼26% as a result of the surface microcracking produced by the laser machining. The membranes have a roughness of ∼2.5 μm and are coated by a layer of nanoparticles produced by the laser ablation. This coating and small roughness is not detrimental for the cathodic polarization of the cells. Conversely, the cathode polarization resistance decreases ∼5% in the 650–850 °C temperature range.