Five‐layer reverse tape casting of IT‐SOFC

Tape casting is a well‐established method for manufacturing thin ceramic layers with controllable thickness and porosity. This study investigates the potential of 10Sc1CeSZ material for the electrolyte and anode layers for intermediate‐temperature solid oxide fuel cells (IT‐SOFC) in an anode‐supported cell (ASC) geometry. In order to use La0.6Sr0.4Co0.2Fe0.8 Oxide (LSCF) cathode material, a Gd0.2Ce0.8 Oxide (GDC) barrier layer is needed; however, thermal expansion coefficient mismatch results in delamination of the GDC from the electrolyte during high temperature sintering when fabricated by conventional tape casting procedures. For the first time, ASCs have been manufactured by a five‐layer tape casting technique; barrier layer, novel composite layer, electrolyte, anode functional layer, and anode substrate. Ni‐ScCeSZ composite cells were tested between 650 and 800°C in H2:N2 fuel (85% H2) on the anode and air on the cathode to yield a maximum power density of .46 W/cm2. These results demonstrate the feasibility of this new five‐layer tape casting technique to produce IT‐SOFC.