Advanced Solid Oxide Fuel Cell Components Enabled through Additive Manufacturing

Most of the current state of the art solid oxide fuel cell (SOFC) stacks are assembled using planar cells, interconnects, gaskets, and insulators in a sequence that requires high level of precision and accuracy. For such conventional assembly approaches, the relatively high manufacturing cost is a key hurdle that prevents the widespread commercialization or adoption of SOFC systems. We are proposing to develop and demonstrate a novel cost-effective additive manufacturing (AM) approach to fabricate novel design SOFC cells and interconnects during Phase I. Ultra-thin film electrode and electrolyte layers will be applied via coefficient of thermal expansion (CTE) matched layering techniques to demonstrate preliminary proof of concept. Our goal will be to demonstrate proof of concept design for an improved cell/stack enabled via AM and to assess the AM process impact on fabrication cost and performance of the cell/stack. Furthermore, we will demonstrate the feasibility of AM process to realize micro/macro structures designed to allow for ideal gas flow channels and gas diffusion, and fabricate and test SOFC structures to demonstrate the improved performance. During Phase II, a sequenced combination AM of support, interconnects, and edge sealing along with CTE matched ceramic layers will be developed. The approach will be refined for a uniform, thin, and defect-free coating that avoids sealing surfaces and mated with AM manifolds. The manufacturing approach will eliminate multiple steps currently required to fabricate the cells, interconnects, reformer, and manifolds. We anticipate that the development of new multi-functional AM technology will not only be beneficial for fuel cell technology but also for wide variety of electrochemical applications such as hydrogen production, gas separation, and batteries.