Manufacturing of anode-supported tubular solid oxide fuel cells by a new shaping technique using aqueous gel-casting

► Anode-supported tubular SOFCs fabricated by using aqueous gel-casting. ► Manufacturing is one of the major focuses of SOFC cost reduction. ► Gel-casting is a method with a short shaping time, high yields and low-cost equipment ► A suitable relation of slurry viscosity, porosity and strength for tubular anodes was found. A new gel-casting technique has been successfully developed to obtain tubular NiO–SDC anode-supported solid oxide fuel cells (SOFCs). Rheological parameters of the ceramic particle suspensions, directly influencing on casting and production, were investigated as a function of process parameters: solid loading, dispersant and agarose amounts. Afterwards, a SDC (Sm 0.2Ce 0.8O 1.9) electrolyte film was deposited on NiO–SDC tubular anode substrates by colloidal spray-coating technique and co-sintering at 1400 °C for 5 h. The shrinkage and microstructure of the sintered cell components were studied. SEM results revealed high porosities of anode (40%) and cathode (La 0.5Sr 0.5CoO 3, LSC), a dense SDC film electrolyte with a thickness of 30 μm and a good adhesion between the electrolyte, and the anode and cathode.