One-Step Fabrication of Protonic Ceramic Fuel Cells Using a Convenient Tape Calendering Method

The present paper reports the preparation of multilayer protonic ceramic fuel cells (PCFCs) using a single sintering step. The success of this fabrication approach is due to two main factors: the rational choice of chemically and mechanically compatible components, as well as the selection of a convenient preparation (tape calendering) method. The PCFCs prepared in this manner consisted of a 30 µm BaCe0.5Zr0.3Dy0.2O3–δ (BCZD) electrolyte layer, a 500 μm Ni–BCZD supporting electrode layer and a 20 μm functional Pr1.9Ba0.1NiO4+δ (PBN)–BCZD cathode layer. These layers were jointly co-fired at 1350 °C for 5 h to reach excellent gas-tightness of the electrolyte and porous structures for the supported and functional electrodes. The adequate fuel cell performance of this PCFC design (400 mW cm−2 at 600 °C) demonstrates that the tape calendering method compares well with such conventional laboratory PCFC preparation techniques such as co-pressing and tape-casting.