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Diffusion-Related SOFC Stack Degradation

Friday, 28 July 2017: 08:40
Atlantic Ballroom 3 (The Diplomat Beach Resort)
N. H. Menzler, A. Beez, N. Grünwald, D. Sebold (Forschungszentrum Jülich GmbH, IEK-1), Q. Fang (Forschungszentrum Jülich GmbH), and R. Vaßen (Forschungszentrum Jülich GmbH, IEK-1)
Solid Oxide Fuel Cell systems for stationary applications should exhibit low degradation (<< 1%/1,000h voltage loss) to ensure long-term operation (> 40,000h). The rather high operation temperature of SOFCs (≥ 700°C) is on the one hand beneficial for oxygen conduction through the ceramic-based electrolyte, but on the other hand all diffusion-related, energetically-driven mechanisms are also increased. This counts less for gas diffusion processes but is more pronounced for solid-state diffusion (surface, bulk, grain boundary). For gas diffusion processes other parameters like gas stream, individual partial pressures and partial pressure gradients are dominating.

Within two different stack tests with four-plane short stacks and their intensive post-test characterization two varying diffusion-related degradation mechanisms have been investigated. One is a short-term (~1250h) test with two different chromium evaporation protection layers on the air side metallic interconnect and frame and the other one is a long-term endurance test (~ 35,000h). For the first stack two planes were coated with a manganese oxide layer applied by wet powder spraying (WPS) while the other two planes were coated by atmospheric plasma spraying (APS) with a manganese-cobalt-iron-spinel layer. Thus the protection layers do not only differ by coating technology but also by material. The voltage loss in the planes with WPS-coated interconnect was markedly higher than in those coated by APS. Finally it turned out that the layers microstructure plays the key role in Cr evaporation minimization. In this stack, gas-phase diffusion is dominating degradation.

In the long-term operated stack, the influence of a diffusing element from the cathodic contact layer towards and through the electrolyte has been characterized. Manganese, presumably originating from the contact layer (but it’s additionally also part of the protection layer), diffuses via solid-state diffusion and reacts while reaching reducing conditions in the fuel compartment with the zirconia-based electrolyte. This interaction forms a secondary sponge-like porous phase at the boundary electrolyte-anode. This secondary phase causes stresses and leads, after growing to big islands of some ten micrometers in diameter, to electrolyte-anode delamination and finally to complete cell failure. For the Mn-related degradation solid state diffusion has been supposed, as the electrolyte is coated by a dense thin-film diffusion barrier layer which suppresses gas diffusion.

Both results indicate that volatile elements (which could either evaporate via gas phase or diffuse via solid state diffusion) should be avoided as they can lead to severe cell, stack and system failure even after thousands of hours of high-temperature operation.