Development of patterned anode supported electrolytes for enhanced solid oxide fuel cell performance

The study investigates the patterning of anode-supported electrolytes (ASEs) for solid oxide fuel cells (SOFCs) by incorporating a mesh during the isostatic pressing process to enhance the electrochemical performance through enlarging the electrode-electrolyte interface area. A variety of mesh types, including woven and non-woven meshes, are tested under different isostatic pressing pressures and temperatures. Their effects on manufacturability, patternability, microstructure, and electrochemical performance are thoroughly evaluated. Electrochemical testing at 800 degrees C demonstrates that the optimized mesh-patterned cell achieves a significant enhancement in peak power density, reaching a maximum of 1.47 W/cm2 compared to 0.81 W/cm2 for the unmodified cell. Additionally, the patterned cell enables a reduction in operating temperature to 700 degrees C while maintaining a performance of 0.72 W/cm2. Despite challenges such as cracks in the cathode layer and localized thickness variations, particularly in cells with deeper patterns, this study provides valuable insights into the relationship between surface patterning and cell performance, offering a promising approach for the development of next-generation anode-supported SOFCs.