Oxide film formation and diffusion processes in near-surface layers of current collectors in solid oxide fuel cells

A method is developed for modifying the surface of current collectors in solid-oxide fuel cells (SOFC) prepared from ferrite stainless steel (Crofer22APU). Diffusion of the protective coating material into the Crofer22APU bulk and reverse diffusion of steel components into the coating are studied. The cross-sectional microstructure and composition are studied by the electron-microscopic technique. The elemental composition of the junction between the current collector and the lanthanum-strontium manganite cathode is studied depending on the time of service-life tests in the SOFC working mode (50–6000 h). The formation of the Cr₂O₃ oxide islet structure on the current collector surface at the steel/coating interface is observed. It is shown that the mutual diffusion of coating components (Ni) and Crofer22APU steel together with the redox reaction at the interface prevent the chromium diffusion to the surface and protect the steel current collector from oxidation.     

Protective coatings for stainless steel for SOFC applications

In this paper, a coating procedure based on spin coating of metal oxide polymer precursors on stainless steel, which decreases the oxide scale growth rate, is evaluated. The yttrium and cobalt solutions were used as polymer precursors, while a ferritic stainless steel Crofer 22 APU was used for the deposition of protective coatings. The thickness of deposited protective film was about ~500 nm. The effectiveness of protective layer was evaluated by cyclic thermogravimetry, oxide scale electrical conductivity, and X-ray diffractometry. The results show that steel coated with yttrium polymer precursor has better properties than uncoated or cobalt-coated sample.     

Mn–Co spinel protective–conductive coating on AL453 ferritic stainless steel for IT-SOFC interconnect applications

This paper presents research on the synthesis and properties of the Mn_1.5Co_1.5O₄ (MC) spinel powder, as well as its application for the preparation of a MC thick film on the AL453 steel to be used for metallic interconnect material in IT-SOFCs. In order to prepare the MC micropowder with excellent homogeneity of the chemical and phase compositions, EDTA gel processes were utilized. In order to improve the contact electrical resistance between an AL453 steel interconnect and the La_0.8Sr_0.2FeO₃ (LSF) cathode and protect the cathode from Cr poisoning, the surface of the AL453 steel was coated with a protective manganese cobaltite spinel matrix using screen printing in combination with an appropriate heat treatment. The oxidation of the AL453/MC composite layer carried out in the air–H₂O gas mixture at 1,073 K for 55 h showed that the spinel coating may serve as an effective barrier against outward Cr diffusion from the AL453 steel and, therefore, significantly inhibit the formation of volatile Cr vapors from the chromia scale. The contact ASR study of the interconnect–cathode interface in the AL453/MC/LSCM/LSF/LSCM/MC/AL453 system carried out in the range of 723?1,073 K in air showed a very large drop in ASR compared to the resistance of the AL453/LSCM/LSF/LSCM/AL453 system without the spinel coating.     

A high performance nano-structure conductive coating on a Crofer22APU alloy fabricated by a novel spinel powder reduction coating technique

A nano-structure conductive coating was fabricated on a Crofer22APU alloy interconnect by an original coating strategy using Mn_0.9Y_0.1Co₂O₄ (MYC) novel spinel nanocrystalline powder. A unique treatment method by which the spinel powder was reduced was used to prepare the green coating. The resulting coating was about 12 μm in thickness, and was composed of MYC nanocrystalline with an average particle size of about 100 nm. The coating was well adhered with the substrate alloy. Less than 4 mΩ cm² of the area specific resistance (ASR) was obtained, and no obvious degradation was observed for a coated alloy (whose coating thickness was about 30 μm) after operated at 800 °C for 538 h under seven thermal cyclings. The coated alloy exhibited excellently electrical performance and long-term stability compared with the uncoated one. The exploration of the novel spinel powder reduction coating technique for alloy interconnect to obtain cheap coatings with excellent microstructure and performance showed a promising prospect for the practical application of solid oxide fuel cells (SOFCs).     

Amorphous sol–gel SiO<Subscript>2</Subscript> film for protection of an orthorhombic phase alloy against high temperature oxidation

Silica coating derived by sol–gel processing was deposited on an orthorhombic phase Ti–22Al–26Nb alloy by dip-coating technique. Isothermal oxidation at 800 and 900 °C and cyclic oxidation at 900 °C in static air of the coated and uncoated specimens were performed to investigate the effect of the silica coating on the oxidation behavior of the Ti–22Al–26Nb alloy by thermogravimetry, SEM and XRD. The average parabolic rate constants of the coated specimens were lower than those of uncoated ones. Additionally, the present film exhibited a beneficial effect on the cyclic oxidation resistance of the alloy in air. TiO₂, Nb₂TiO₇ or AlNbO₄ were the main phases formed on the alloy. The thin film could inhibit the growth of the oxides. The possible mechanism of the thin film on the oxidation behavior of the alloy was discussed.     

(Mn,Cu)3O4-based conductive coatings as effective barriers to high-temperature oxidation of metallic interconnects for solid oxide fuel cells

(Mn,Cu)₃O₄-based conductive oxides are examined as protective coatings to improve the surface stability of metallic interconnects for solid oxide fuel cells at high temperatures. Nano-sized Mn_3???x Cu _x O₄ materials with various Cu contents (x?=?1.0–1.5) are synthesized and a composition-structure–property relationship is experimentally determined. The Cu content (x) has a significant influence on phase stability as well as sintering, electrical, and thermal expansion characteristics. Thin and dense Mn_3???x Cu _x O₄ coatings are fabricated on the interconnects (Crofer 22 APU) by a slurry coating process and subsequent heat treatment. The coated interconnects exhibit area-specific resistances as low as 7.1–15.0 mΩ cm² at 800 °C. The electrochemical cell shows no performance degradation in the presence of the Mn_3???x Cu _x O₄-coated interconnect. The results indicate that the Mn_3???x Cu _x O₄ coatings act as an effective barrier to high-temperature oxidation of the metallic interconnects.     

Protective coatings based on Mn-Co spinel for current collectors of solid oxide fuel cells

The method of electrostatic spray pyrolysis was designed to apply protective coatings based on Mn-Co spinel to ferrite stainless steels (Crofer22APU and 08Kh18T1). The comparative thermogravimetric (TG) studies of ferrite stainless steels with and without protective coatings were carried out. The electrochemical characteristics of protective coatings exposed to long current loading were studied. The formation processes of Cr₂O₃ oxide films were studied at the contact of ferrite stainless steel with La_0.8Sr_0.2MnO₃ ionic and electronic conductor. The coatings of Mn-Co spinel were shown not preventing formation of continuous oxide film on the stainless steel surface.     

Tribo-corrosion behavior of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel

In this investigation , Zn-Ni-Cu and Zn-Ni-Cu-TiB₂ were coated on a mild steel specimen using a high velocity oxy fuel thermal spray (HVOF) process. The surface morphology and coated powder distribution of coated specimens were characterized using scanning electron microscope (SEM), energy dispersive spectroscopy (EDS), and X-ray-Elemental mapping. The pin-on-disc (ASTM G99-17) method was used to examine the wear resistance of the coated and uncoated mild steel specimens. Both coated Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on mild steel saw reduced wear volume loss than uncoated mild steel. The coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on Mild Steel were put through a scratch test to determine the adhesion strength of the coating with the substrate. The adhesion strength of coated Zn-Ni-Cu and Zn-Ni-Cu TiB2 mild steel was higher than that of untreated mild steel, indicating a solid link between the coating and substrate and minimal delamination. Using the Vickers hardness test to measure the hardness caused by the coating, it was shown that coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel had significantly higher hardness than uncoated mild steel. Using ASTM G1-03 and ASTM G-31 standards, a 0.2 M HCl immersion cycle test was conducted for 28 days to test the corrosion resistance of coatings in an acidic media (672Hrs). When compared to Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel, the weight loss for the uncoated mild steel was significantly larger. Additionally, XRD examination showed that coated samples had less rust on their surface than uncoated samples. Both Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on Mild Steel were anti-corrosive, as evidenced by increased corrosion potential and reduced corrosion current density when compared to uncoated mild steel, according to electrochemical impedance spectroscopy (EIS)/Tafel study in 0.2 MHCl. The outcomes of each test were very encouraging and demonstrated the durability of these coatings against wear and corrosion.     

High-Temperature Oxidation Resistance of PDC Coatings in Synthetic Air and Water Vapor Atmospheres

This work is aimed at the development and investigation of the oxidation behavior of ferritic stainless-steel grade AISI 441 and polymer-derived ceramic (PDC) protective coatings. Double-layer coatings of a PDC bond coat below a PDC top coat with glass and ceramic passive fillers’ oxidative resistance were studied at temperatures up to 1000 °C in a flow-through atmosphere of synthetic air and in air saturated with water vapor. Investigation of the oxide products formed at the surface of the samples in synthetic air and water vapor atmospheres, at different temperatures (900, 950, 1000 °C) and exposure times (24, 96 h) was carried out on both uncoated steel and steel coated with selected coatings by scanning electron microscopy (SEM) and X-Ray diffraction (XRD). The Fe, Cr₂O₃, TiO₂, and spinel (Mn,Cr)₃O₄ phases were identified by XRD on oxidized steel substrates in both atmospheres. In the cases of the coated samples, m- ZrO₂, c- ZrO₂, YAG, and crystalline phases (Ba(AlSiO₄)₂–hexacelsian, celsian) were identified. Scratch tests performed on both coating compositions revealed strong adhesion after pyrolysis as well as after oxidation tests in both atmospheres. After testing in the water vapor atmosphere, Cr ions diffused through the bond coat, but no delamination of the coatings was observed.     

Corrosion resistance of amorphous AlPO4 coating in salty atmospheres

The objective of the present study was to introduce a cost-effective and environmentally friendly coating to improve the corrosion resistance of the structures located in salt water. The coating solution, based on amorphous aluminum phosphate composition, was synthesized by sol–gel process and applied to AISI 304 stainless steel by dip coating technique. X-ray diffraction, scanning electron microscopy, and energy dispersive X-ray spectroscopy analyses were employed to investigate the phase composition and morphology of the coating. Corrosion behavior of the uncoated and coated samples was investigated using standard salt spray test, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl solution. Salt spray test results for the bare substrate revealed a corrosion rate of six-time greater than that of the coated surface after 168 hr exposure time. Electrochemical test results declared that the amorphous AlPO₄ coating decreased the corrosion current density of the AISI 304 stainless steel by 10 orders of magnitude. Furthermore, according to the corresponding EIS measurements, the coated surface exhibited a superior anti-corrosion performance than uncoated sample. Overall, the results declared that the amorphous AlPO₄ coating could be a good choice for surface protection of stainless steel against electrochemical corrosion in salty environments.     

Evaluation of in vitro bioactivity and MG63 Oesteoblast cell response for TiO2 coated magnesium alloys

The present investigation reports TiO₂ coating on magnesium alloy AZ31 by sol–gel method via dip coating technique. TiO₂ coated surface was characterized by thin film X-ray diffraction (TF-XRD), Fourier transform infrared red (FT-IR) spectroscopy, scanning electron microscopy (SEM) with energy-dispersive X-ray (EDX) spectroscopy, atomic force microscopy (AFM) and transmission electron microscopy (TEM) techniques. From TF-XRD results, the peaks at 2θ values of 25.14, 32.12, 68.73 and 70.11 confirm the presence of TiO₂. The TiO₂ is crystalline in nature and the crystallite size is about 32.4 nm. SEM-EDX, TEM and AFM show that the coated surface is uniform and nanoporous. FT-IR analysis shows that the peak in the range of 692 cm^?1 is assigned to Ti–O–Ti stretching vibration. Contact angle measurements show that the coating is hydrophilic in nature. Bioactivity of the coating in simulated body fluid (SBF) was also examined, the hydroxyl functionalized surface greatly enhances the hydroxyapatite growth. The potentiodynamic polarization studies prove that the corrosion resistance of the TiO₂ coated surface after immersion in SBF for 7 days is improved dramatically. Cell adhesion studies confirm the increased cell attachment on TiO₂ coated surface when compared to uncoated alloy, due to less amount of Mg ion release from the substrate in the culture medium.     

Effects of organic-inorganic hybrid coatings on durability of cross-linked polyethylene

Cross-linked polyethylene (XLPE) films have been coated with nanostructured hybrid organic-inorganic coatings in order to improve their durability. For this purpose, bi- and mono-layer coatings containing different amount of silica and different organic polymers have been prepared through sol-gel reactions and applied to XLPE commercial films. The thermo-oxidative stability, electrical strength and conductivity of XLPE coated films have been investigated after ageing in air at temperatures above the on-service conditions, i.e. at 105 and 120 °C for 1900 and 600 h, respectively. The performed investigations (FT-IR, DSC, TGA and electrical properties) showed that all the coatings tested were able to strongly protect XLPE against oxidation, and that the coating with a PVOH/SiO₂ layer gave the best protection. The increase of thermal resistance induced by the coatings reflects on the electrical strength after ageing, which is higher for coated samples than for uncoated ones. Moreover, while ageing has only a slight effect on electrical conductivity in different coated samples, a strong increase of conductivity was observed after ageing for highly oxidated uncoated samples.     

Physicochemical properties of Mn1.45Co1.45Cu0.1O4 spinel coating deposited on the Crofer 22 H ferritic steel and exposed to high-temperature oxidation under thermal cycling conditions

Journal of Thermal Analysis and Calorimetry - The Crofer 22 H ferritic steel substrate was coated with an Mn1.45Co1.45Cu0.1O4 spinel by means of electrophoresis. After high-temperature oxidation...     

Preparation and performance of (Co,Mn)3O4 spinel coating on Crofer alloy by composite electrodeposition and step-heating thermal conversion

The preparation and performance improvement of the spinel coating on the surface of ferritic alloy is of wide interest for its application in the metallic interconnects of the solid oxide fuel cells (SOFCs). The Co Mn₂O₃ composite coating is prepared on the surface of the Crofer alloy by the composite electrodeposition method. A step-heating thermal conversion process is subsequently used to convert the composite coating into a spinel coating, while a direct-heating process is implemented as the control experiment. Isothermal oxidation tests are then carried out for the prepared samples in order to present the high temperature performance. Scanning electron microscopy (SEM), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and area-specific resistance (ASR) are used to analyze the properties of the matrix and coatings. The experimental results reveal that the coatings by step-heating thermal conversion exhibit better performance of electrical conductivity and oxidation resistance than the coatings by direct-heating process. Furthermore, with the increase of oxidation time, the atomic proportion of Cr element diffusing to the surface of the matrix is maintained at about 3%–4% for the samples with spinel coatings by step heating, which effectively prevent the Cr volatilization in the matrix. The preparation of spinel coatings on the ferritic alloy by composite electrodeposition and step-heating thermal conversion is helpful to stimulate new ideas for the development of reliable and cost-effective metallic interconnect.     

Regularities of high-temperature oxidation of current collectors of solid oxide fuel cells due to diffusion processes in subsurface regions

A complex study of regularities of oxidative reactions is carried out in subsurface layers of current collectors of solid oxide fuel cells manufactured of Crofer 22APU or Crofer 22H stainless steel. The methods of scanning electron microscopy, energy dispersive X-ray analysis, and Raman spectroscopy are used to study the distribution of the main steel elements in subsurface layers of current collectors as dependent on the operation time under the conditions of a cathodic chamber of solid oxide fuel cells. A mechanism of the process is suggested and contact resistance between the current collector and LSM cathode is calculated using the model of a Schottky barrier for a metal–semiconductor junction.     

Structure,hydrophilicity and corrosion resistance of sol–gel derived Ag-containing TiO2 film on plasma nitrided 316L stainless steel

Pure and Ag-containing TiO₂ films (Ag/Ti = 3.3 at.%) are coated on plasma nitrided 316L stainless steel by sol–gel method for biomedical applications. The addition of Ag does not cause obvious change in TG–DSC curves of the dried gels. The rough surface generated by plasma nitriding and the addition of Ag improve structural integrity of the TiO₂ films. X-ray diffraction reveals N loss and oxidation of the nitride layer during calcination treatment, and peaks of Ag or its oxides are not detected. X-ray photoelectron spectroscopy analysis indicates that Ag presents as metallic state in the film. Water contact angles of the coating samples decrease with UV irradiation treatment. The potentiodynamic polarization tests in a Ca-free Hank’s balanced salt solution show that the TiO₂ coated samples have decreased corrosion resistance due to N loss and oxidation of the nitride layer. The methods for crystallization of TiO₂ gel layers with minimized or avoided structural changes of the nitride layer will be tried in order to improve corrosion resistance of the duplex treated 316L stainless steel.     

Electrochemical cell with solid oxide electrolyte and oxygen pump thereof

The paper presents the scientific basis and technical implementation of a method for obtaining oxygen by extraction from air using an electrochemical cell based on a solid oxide cell (SOC) with anion-conducting solid electrolyte. A nanopowder of a weak aggregate of the YSZ solid electrolyte and LSM fine powder was used to manufacture SOC. The electrolyte-electrode SOC structure was formed as a tube by joint pressing of functional layers and the further co-sintering at the temperature of 1200°C. The characteristics of an electrochemical cell of the oxygen pump based on a thin-wall tube of the YSZ supporting electrolyte (150 μm) with symmetrical electrodes based on LSM (∼20 μm) are studied. A prototype of a compact oxygen generator (oxygen pump) is developed and manufactured with an electrochemical part based on three serially connected SOCs. The connection is implemented in the form of metallic couplings of the Crofer 22 APU steel. The method of reaction magnetron sputtering was used to protect current leads from corrosion by applying a coating based on a Mn _x Co_{3 − x} O₄ spinel. The efficiency of a demonstration prototype at 800°C was 9 l/h at the power consumption of 50 W. The current density through SOC was 1.1 A/cm². The prototype was designed to contain no noble metal components. It is shown that the engineering approach applied allows manufacturing effective nanostructural SOCs and devices on their basis.     

Influence of protective layers on SOFC operation

Corrosion kinetics of ferritic alloys/steels (Crofer22APU, ITMLC, ZMG232L) were studied at high temperature. An extent of corrosion was evaluated by measuring the oxide scale thickness and the weight gain as a function of heating time. It is shown that even porous layer applied to interconnect can significantly reduce the rate of the steel oxidation. Contribution of the “oxide component” into the total degradation of the SOFC stack performance is estimated. Different protection materials and combinations were tested to analyze their influence on the processes of high temperature oxidation and long-term degradation of Fe-Cr steels. It has been shown that “more soft” materials on the basis of spinels (Mn(Co_{1 − x} Fe _x )₂O₄, Cu_{1 − x} Ni _x Mn₂O₄) are most suitable materials for the use as protective layers in comparison to perovskites. The efficiency of different protective materials was also tested in the real SOFC stacks designed in cooperation with company Staxera GmbH. It has been shown that applied spinel materials can effectively increase the long-term stability of the SOFC stacks.     

Photocatalytic TiO2 coatings on limestone

The application of photocatalytic coatings on stone has been investigated for providing surface protection and self-cleaning properties. Sol–Gel and hydrothermal processes were used to synthesise TiO₂ colloidal suspensions and coatings with enhanced photocatalytic activity without any thermal curing of the coated stone. The stone was a porous limestone (apulian sedimentary carbonatic, calcite stone). Films and powders prepared from TiO₂ sols were studied using X-ray diffraction to evaluate the microstructure and identify rutile and anatase phases. A morphological and physical characterisation was carried out on coated and uncoated stone to establish the changes of appearance, colour, water absorption by capillarity and water vapour permeability. The photocatalytic activity of the coated surface was evaluated under UV irradiation through NO _x and organics degradation tests. The performances of the synthesised TiO₂ sols were compared with commercial TiO₂ suspension. Since the coating doesn’t need temperature treatments for activating the photocatalytic properties, the nano-crystalline hydrothermal TiO₂ sols seem good candidate for coating applications on stone that cannot be annealed after the coating application.     

Electrochemical behavior of uranyl in ionic liquid 1-butyl-3-methylimidazolium chloride mixture with water

Electrochemical behaviors of U(VI) in 1-butyl-3-methylimidazolium chloride (C₄MimCl) with various water contents investigated by chronopotentiometry and cyclic voltammetry. The electrochemical reduction of U(VI) was identified to follow two processes: a lower valence intermediate U(V) was initially formed at the potential of ca. ?0.2 V(vs. Ag wire). Then, further deposition of UO₂ was followed at around ?0.8 V. Little amount of water (1–4 wt%) in C₄MimCl, however, has an effect on the U(VI) reduction by changing the current density of the redox reaction and the diffusion coefficient of U(VI) in C₄MimCl. The deposited product by potentiostatic electrolysis on the surface of stainless steel electrode was characterized by the scanning electron microscopy (SEM), energy dispersive X-ray (EDX) and X-ray diffraction (XRD) methods. Although the electrodeposited black film was amorphous, the electrochemical reduced product of U(VI) can be still confirmed to be UO₂ by XRD after the crystallization of the amorphous deposits at 1,073 K in nitrogen atmosphere.