The design and manufacturing of scandia-ceria stabilized zirconia ceramics for use as electrolyte material in solid oxide fuel cells

In order to increase the efficiency and economic viability of solid oxide fuel cells (SOFCs), new materials for the cathode, anode, and electrolyte of the cells must be found. SOFCs have a ceramic electrolyte, which is commonly made of fully stabilized zirconia. Due to increased material degradation rates at elevated temperatures ( ~ 1000°C) of current SOFCs, materials for the manufacture of intermediate temperature SOFCs, which operate in the range of 700-800°C, are currently under study. In this study, the manufacturing process for scandia-ceria stabilized zirconia powder (1 0mol¾ Sc2O3, lmol¾ CeO2, 89mol% ZrO2), from Daiichi Kigenso Kagaku Kogyo (DKKK) is developed, including tape casting and sintering procedures to result in pellets of high enough quality to produce single button cells. It is found that a slip prepared with about 44 wt% zirconia powder and increased proportions of solvents, dispersant, binder and plasticizers produces a favorable viscosity of about 7 40cP after deairing, and will produce tapes that are reasonably smooth and of stable thickness. Since the single cell will be structurally based upon this electrolyte material, the physical properties of the pellets are important, in addition to the electrochemical properties of the constituent materials. Tapes cast at 500µm, at 50% feed rate with a 50°C drying temperature, laminated and sintered at 1500°C on setter plates will produce flat, smooth, stiff pellets for the production of single buttons for use as the electrolyte. Cathode (50-50 mixture of La0.6Sr0_4Fe0_8Co0.2O3 + 20mol% Gd2O3 80mol% CeO2) and Anode (35 wt% DKKK powder, 65 wt% NiO) materials were hand-painted on to either side of the electrolyte and sintered to create a complete SOFC cell consisting of cathode, electrolyte, and anode