Bilayered anode supports for planar solid oxide fuel cells: Fabrication and electrochemical performance

[Display omitted] •Fabrication route of bilayer planar anode supports with bilayer solid electrolyte.•Anode supports were manufactured by tape casting and magnetron sputtering.•Microstructure and mechanical strength were studied to optimize preparation route.•Power density of a model SOFC based on support achieved 1.8 W/cm2 at 800 °C. Bilayered substrates for anode-supported solid oxide fuel cells (SOFCs), made of NiO and 10 mol.% Sc2O3 and 1 mol.% Y2O3 co-stabilized zirconia (10Sc1YSZ), were produced employing the tape casting technique. The optimization of the pore former (rice starch) content in the starting suspension and thermal treatment conditions provide necessary porosity, simultaneously maintaining sufficiently high mechanical strength of the composite measured by the three-point bending method. Bilayered gas-tight solid electrolyte films of 8 mol.% Y2O3 stabilized zirconia and 10 mol.% Gd2O3 doped ceria (8YSZ/10GDC) were deposited by magnetron sputtering, followed by annealing at 1200 °C. The area-specific power density of a model SOFC achieved 1.8, 1.4, and 0.9 W/cm2 at 800, 750, and 700 °C, respectively.