Electrophoretic Deposition of Zirconia Thin Film on Nonconducting Substrate for Solid Oxide Fuel Cell Application

Electrophoretic deposition (EPD) of 8mol% yttria-stabilized zirconia (YSZ) electrolyte thin film has been carried out onto nonconducting porous NiO-YSZ cermet anode substrate using a fugitive and electrically conducting polymer interlayer for solid oxide fuel cell (SOFC) application. Such polymer interlayer burnt out during the high-temperature sintering process (1400 degrees C for 6h) leaving behind a well adhered, dense, and uniform ceramic YSZ electrolyte film on the top of the porous anode substrate. The EPD kinetics have been studied in depth. It is found that homogeneous and uniform film could be obtained onto the polymer-coated substrate at an applied voltage of 15V for 1min. After the half-cell (anode+electrolyte) is co-fired at 1400 degrees C, a suitable cathode composition (La0.65Sr0.3MnO3) thick film paste is screen printed on the top of the sintered YSZ electrolyte. A second stage of sintering of such cathode thick film at 1100 degrees C for 2h finally yield a single cell SOFC. Such single cell produced a power output of 0.91W/cm(2) at 0.7V when measured at 800 degrees C using hydrogen and oxygen as fuel and oxidant, respectively.