Development of Multiple Ceramic Coatings on Porous Tubular Metal Support

Dip coating was used to develop anodic half-cell for micro-tubular metal-supported solid oxide fuel cells (MS-SOFCs) economically. Ni–scandia-stabilized zirconia (SSZ) and SSZ were used as anode functional layer and electrolyte, respectively. Successive coatings of the SOFC functional layers were applied onto the porous metallic support using a dip coating technique. Additionally, to prevent delamination between the metal support and anode functional layer, an intermediate layer consisting of stainless steel powder, Ni, and yttria-stabilized zirconia (YSZ) was introduced. After coating, the individual layers were fired in a reducing atmosphere at 1000 °C followed by co-sintering of metal/anode/electrolyte multilayers at 1350°C. Microstructure of the sintered cells was characterized using scanning electron microscopy (SEM). General problems encountered during the fabrication of anodic half-cell for MS-SOFCs by a cost-effective dip coating followed by co-sintering route have been investigated. The sintering conditions and multilayer designs were studied to minimize the metal support oxidation and ceramic layer peeling during co-sintering.