Thursday, 27 July 2017: 10:40
Atlantic Ballroom 3 (The Diplomat Beach Resort)
Plasma spraying has been widely applied to deposit ceramic coatings and is also considered as promising cost-effect manufacturing process to deposit electrolyte and ceramic interconnect for solid oxide fuel cells. However, it is generally difficult to deposit highly dense electrolyte and interconnect which can be directly applied to SOFC operation in the as-prepared state following the conventional process routine. In this paper, a novel approach based on the critical bonding temperature concept is presented to prepare dense electrolytes by plasma spraying. YSZ and LSGM are used as typical electrolytes, and LaxSr1-xCrO3 and LaxSr1-xTiO3 are used as typical interconnect. The individual ceramic functional layers are deposited at a deposition temperature higher than the critical bonding temperature. The compositions, microstructure, electric properties and gas permeability of different ceramic deposits are characterized. It is revealed that both plasma-sprayed electrolytes and interconnects present a gas permeability less than 1x10-7 cm4gf-1s-1 and can be directly applied to SOFC high temperature operation. Moreover, the deposited electrolytes present an ionic conductivity of over 80% sintered bulk materials. Along with the composition control approach during plasma spraying, high performance electrolyte and ceramic interconnect are deposited by atmospheric plasma spraying. Moreover, the excellent performance of the electrolyte and interconnect is also demonstrated by the output performance of assembled SOFC cells with the APSed functional layers.