3D Porous Nickel Anode for Low Temperature Thin Solid Oxide Fuel Cell Applications

A simple fabrication process for a 3D porous nickel anode for a thin film solid oxide fuel cell (SOFC) is developed. The 3D porous nickel anode is fabricated using a metal/proppant mixing method followed by pressing and heat treatment. The anode bulk possesses a high porosity which is required for efficient delivery of fuel to the cell. Following fabrication, the anode's surface is processed by means of mechanical, chemical, and ion etching to minimize surface roughness and reduce the surface pore size allowing for the deposition of a high quality, pore-free, thin electrolyte. Yttria-stabilized zirconia is used for the thin film electrolyte layer followed by deposition of a thin film La0.6Sr0.4Co0.2Fe0.8O3−d cathode layer to complete the thin film SOFC. The fabricated cell performs with a very stable output power of 130 mW cm−2 at temperatures of the order of 450 °C. This anode is not only easy to shape, weld, and recycle but is also very economic.