Thick films of YSZ electrolytes by dip-coating process

Yttria stabilized zirconia (YSZ, 8% Y2O3) thick films were coated on porous Ni-YSZ substrates using the dip-coating process and a suspension with a new formulation. The suspension was obtained by addition of a polymeric matrix in a stable suspension of a commercial YSZ (Tosoh) powders dispersed in an azeotropic MEK-EtOH mixture. The green layers were densified after an optimization of the suspension composition. YSZ Tosoh particles encapsulated by a zirconium alkoxide sol and added with colloidal alkoxide precursor are used to load the suspension. The in situ growth of these colloids increases significantly the layers density after an appropriated heat treatment. The obtained films are continuous, homogeneous and 20 μm thick. Different microstructures are obtained depending on the synthesis parameters of the suspension.