A multiscale-architecture solid oxide fuel cell fabricated by electrophoretic deposition technique

Solid oxide fuel cells (SOFCs) are widely utilized for energy conversion applications, due to their remarkable electrochemical performance, economical and environmental points of view. In the present study, a multiscale-architecture SOFC, consisting of NiO-YSZ anode, NiO-YSZ anode functional layer (AFL), YSZ electrolyte, and bi-layered LSM/LSM-YSZ cathode is fabricated; where innovatively all the layers are deposited by environmentally-friendly electrophoretic deposition. The porous anode support consisting of 67 wt% NiO-YSZ (60:40 wt%)-33 wt% graphite is prepared by pressing method. Identifying and investigations on the structure and morphology of the samples are carried out by field emission scanning electron microscopy (FE-SEM), representing the high porosity of different layers. Good peak power densities of 0.477 (with H2 fuel) and 0.420 W cm−2 (with CH4 fuel) at open-circuit voltages (OCV) of 0.89 and 0.80 V are achieved at the operating temperature of 800 °C. These lower OCVs than the theoretical OCV value, confirm the porous structure of the YSZ electrolyte. •The all-porous SOFC was composed of NiO-YSZ, NiO-YSZ (AFL), YSZ and LSM/LSM-YSZ.•EPD processes were carried out at a voltage of 30 V and deposition time of 3 min.•No crack was seen at the interfaces indicating the good integration between layers.•Peak power densities of 0.477 and 0.420 W cm−2 were achieved using H2 and CH4 fuels.