Sr-doped LaFeO3 thin coatings for protection of ferritic stainless steel interconnects in solid oxide cells: A study on Cr-barrier and electrical properties

•Thin perovskite conversion coatings for a Solid Oxide Cell steel interconnect.•Coatings grown with a dual perovskite/spinel layer and an overall 1-3µm thickness.•The role of nitrate accelerant on the coating structure was investigated.•With optimal nitrate addition a three-layer structure was thermally formed.•The three layer structure promoted superior Cr barrier with good ASR properties. A high-temperature conversion process in molten carbonate baths was applied to produce thin Sr-doped LaFeO3 perovskite coatings on the surface of a K41 steel for interconnect applications in Solid Oxide Cells. Two conversion coatings with identical structure and phase composition, but slightly different thickness were produced in nitrate-accelerated baths containing the nitrate additive at two concentration levels. The as-prepared coatings consisted of a dual-layered perovskite-spinel structure with a top sub-micrometric Sr-doped LaFeO3 layer grown onto a micron-range thick inner Fe-Cr spinel oxide layer. Both coatings showed high protection against oxidation and chromia scale formation at 700°C. Further, excellent Area Specific Resistance (ASR) behavior was found for both coatings at 700°C, although an optimal balance of ASR and Cr-diffusion barrier properties was achieved with the coating produced in the lower nitrate content bath (N-02 coating). The causes for the enhanced barrier properties of the N-02 coating were ascribed not to a different coating thickness, but rather to the evolution of the pristine dual-layer into a more impervious three-layer structure during oxidation aging at 700°C. The evolved structure was formed by decomposition of the pristine sub-coating Fe-Cr spinel into two new spinel sublayers: an outer ferrite and an inner chromite layer, whereas the top thin-film perovskite layer remained essentially unaltered. Partial change in the Fe oxidation state and other possible causes involved in the observed decomposition of the pristine Fe-Cr spinel layer during the thermal aging are analyzed and discussed. Measurements of ASR activation energy indicated that the contact resistance behavior of the thin perovskite coatings was dominated by the internal spinel layer conductivity.