Fabrication of multi-layered solid oxide fuel cells using a sheet joining process

Ceria-based electrolytes can be used in solid oxide fuel cells (SOFCs) that operate at intermediate-temperature due to their high ionic conductivity. However, the difficulty in fabricating a thin and dense ceria-based electrolyte on an anode support is well-known. In this study, a new sheet joining process is suggested to produce a thin and dense ceria-based electrolyte for anode-supported SOFCs. The main idea used with the sheet joining process is a combination of a sheet cell fabricated by tape casting, and an anode pellet, fabricated by pressing. The maximum power density of a single cell, fabricated by the sheet joining process, is 0.315 W cm−2 at 600 °C in a power generation test when Pr0.3Sr0.7Co0.3Fe0.7O3−δ was used as the cathode material. The performance durability of a single cell is tested over 1000 h of operation in which a dense electrolyte was observed to survive.