Thermogravimetry study of the effectiveness of different reducing agents during sintering of Cr-prealloyed PM steels

The La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF48) cathode material was used as a protective-conducting coating on an interconnect made of Crofer 22 APU ferritic steel intended for application in intermediate-temperature solid oxide fuel cell (IT-SOFC) stacks. The LSCF48 coating was deposited on the surface of the steel via screen-printing followed by appropriate thermal treatment. The oxidation kinetics of the Crofer 22 APU steel—uncoated and coated with LSCF48—approximately obeys the parabolic rate law in air at 1,073 K under isothermal and cyclic oxidation conditions. The oxidation rate for uncoated steel is higher than that for coated steel. SEM–EDS and XRD investigations showed that the LSCF48 coating interacts with the steel during long-term oxidation in the afore-mentioned thermal conditions, and an intermediate multilayer interfacial zone is formed. This intermediate layer leads to lower area specific resistance in air at 1,073 K in comparison to the Crofer 22 APU steel without surface modification.     

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.     

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.     

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.     

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.     

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.     

High-temperature carbon-coated aluminum current collector for enhanced power performance of LiFePO4 electrode of Li-ion batteries

The charge/discharge capacity and cycle stability at high C-rate of LiFePo₄ (LFPO) electrodes using three types of Al current collectors, including smooth un-etched Al foil, anodization-etched Al foil, and the etched Al foil covered with a conformal C coating grown at 600 °C in CH₄, were investigated. The results unequivocally demonstrate the strong effects exerted by the surface structure and composition of the Al current collectors on the power performance. In particular, the use of the C-coated current collector not only remarkably increases the power-delivering capability, by 3–7-fold based on different comparison criteria, of the LFPO electrode, but also greatly enhances its cycle stability under high C-rate (5C). The rate enhancement exceeds that of a low-temperature organic-bound C-coating reported in the literature. The enhancements are consistent with observed reduction in overall charge-transfer resistance, which can be attributed to the removal of the native insulating oxide surface layer of the current collector and to the improved adhesion at the active layer/current collector interface. This current collector is also applicable to other cathode and anode (e.g., Li₄Ti₅O₁₂) materials of Li-ion batteries for the same beneficial effects.     

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).     

Oxidation kinetics study of the iron-based steel for solid oxide fuel cell application

Kinetics of oxidation of Fe-Cr steel containing 25 wt.-percent Cr was studied as a function of temperature (1023–1173 K) for up to 480 h in flowing air, which corresponds to SOFC cathode environment operating conditions. The oxidation process was found to be a parabolic, suggesting that the diffusion of ionic defects in the scale is the slowest, rate determining step and it occurs predominantly by short-circuit diffusion paths. Comparison of the determined activation energy of oxidation of the studied steel with literature data indicates that at 1098–1173 K the chromia scale grows by the outward solid-state diffusion of chromium interstitials, whereas at 1023–1098 K — through a significant contribution of counter-current oxygen/chromium diffusion along Cr₂O₃ grain boundaries. The oxide scales were composed mainly of Cr₂O₃ with a continuous thin Mn_1.5Cr_1.5O₄ spinel layer on top of the chromia scale. The oxidation test results on Fe-25Cr steel demonstrate the applicability of the commercial type DIN 50049 stainless steel as interconnect for SOFC. This revised version was published online in July 2006 with corrections to the Cover Date.     

Influence of cerium oxide on properties of glass–ceramic sealants for solid oxide fuel cells

The influence of the cerium oxide concentration on the properties of glasses and glass ceramics of the SiO₂–Al₂O₃–CaO–Na₂O–MgO–K₂O–B₂O₃–CeO₂ system as potential adhesive and sealing materials for solid oxide fuel cells was studied. According to the data of differential scanning calorimetry, variation of the CeO₂ concentration does not appreciably influence the glass transition and crystallization temperatures of glasses. As the cerium oxide concentration is increased, the linear thermal expansion coefficient increases for the glasses but decreases for the partially crystalline samples. The gluing temperature of the glass sealants prepared allows their use for joining YSZ solid electrolytes with interconnectors of Crofer22APU type in solid oxide fuel cells..     

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.     

Ion Transport Across Liquid|Liquid Interfacial Boundaries Monitored at Generator‐Collector Electrodes

Anion transfer processes at a liquid|liquid interface were studied with an interdigitated gold band array electrode. The organic phase, 4‐(3‐phenylpropyl)‐pyridine containing Co(II)phthalocyanine, was immobilised as random droplets at the electrode surface and then immersed into aqueous electrolyte. Oxidation of Co(II)phthalocyanine at the generator electrode was shown to be associated with anion transfer from the aqueous into the organic phase. The corresponding back reduction at the collector electrode with anion expulsion was delayed by the anion/cation diffusion time across the interelectrode gap. A working curve based on a finite difference numerical simulation model was employed to estimate the apparent diffusion coefficients for anions in the organic phase (PF₆^?4^?3^?). Potential applications in ion analysis are discussed.     

LaNi0.6Fe0.4O3 as a cathode contact material for solid oxide fuel cells

In solid oxide fuel cells (SOFCs) the interconnects electrically link air and fuel electrodes on either side to produce a practical electrical power output. The long-term stability of intermediate temperature (650–800 °C) SOFC operation strongly depends on the composition of the ferritic steel interconnection material and the steel/ceramic interface. During high-temperature operation the Cr-containing ferritic steel forms an oxide scale at its surface, thereby causing high ohmic electrical contact resistance when connected to the surface of an electronically conducting ceramic cathode material. In the long run, the vaporization of Cr species from these oxide scales also affects the cathode activity, eventually leading to cell deterioration. One way of overcoming the problem is to incorporate another electronically conducting ceramic compliant layer, commonly known as the contact layer, between the cathode and metallic interconnect. In this contribution, LaNi_0.6Fe_0.4O₃ was tested as a cathode contact material. Its performance at 800 °C in the form of a ~50 μm thick film applied on two ferritic steel compositions was examined. After 600 h of testing, contact resistances of 60 and 160 mΩ cm² were obtained. The different values are explained by the variation in steel composition.     

(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.     

Improving the oxidation resistance of AlCrN coatings by tailoring chromium out-diffusion

In this work, we have studied the improvement on the oxidation resistance of AlCrN-based coatings by adding a subsurface titanium nitride barrier layer. Since oxidation is interrelated with the inward diffusion of oxygen into the surface of Al_xCr_1−xN (x = 0.70) coatings and the outward diffusion of Cr to the surface, the oxidation behaviour of the aluminium-rich AlCrN coatings can be tuned by designing the coating in an appropriate layered structure. The buried depth of the embedded layer and the oxidation time were varied, and the changes in the AlCrN/TiN depth composition profiles and surface oxidation stoichiometry were analysed by means of Glow Discharge Optical Emission Spectroscopy (GDOES) and Cross Sectional SEM (X-SEM) maps. It was observed that when a TiN diffusion barrier of 300 nm was deposited near the top surface (500 nm from the surface) the inhibition of the inward diffusion of oxygen and formation of beneficial alumina surface layers was promoted and consequently an increase of the oxidation resistance is achieved. This is explained in terms of a limited surplus of chromium from the coating to the surface. This was corroborated after performing experiments using CrN as embedded barrier layer which resulted in a continuous surplus of chromium to the surface and the formation of Cr-rich oxides. GDOES, in combination with X-SEM elemental maps, was proved to be a fast and accurate technique to monitor composition in-depth changes during oxidation, providing unique information regarding the oxide structure formation.     

The electrochemistry of nanostructured Ni–W alloys

This work reports on the features that Ni–W nanostructured alloys, electrodeposited on carbon steel by different current pulse programs, may present depending on their surface morphology and surface composition. The Ni–W nanostructured coating, with a cauliflower structure, lack of fragility, and high WO₃/W surface composition ratio, is a stable electrode to catalyze hydrogen evolution reaction, exceeding bulk and electrodeposited Ni catalytic activity. Also, the nanostructured alloys must have a low WO₃/W surface composition ratio for Ni and its oxides to provide protection and improve corrosion resistance in sulfate media.     

涂碳铝箔对磷酸铁锂电池性能影响研究

本文研究了使用涂碳铝箔作为正极集流体磷酸铁锂电池的性能。研究对比了使用普通铝箔和涂层铝箔的10 Ah软包磷酸铁锂电池的主要性能。研究表明:使用涂层铝箔不但可以提高磷酸铁锂材料的粘结性,而且使用导电涂层可以有效降低正极材料和集流体的接触内阻,从而减小电池内阻,提高电池倍率性能。与使用普通铝箔作为集流体相比,通过使用涂碳铝箔可以使得电池的内阻降低65%左右,但是,磷酸铁锂正极材料的克容量却偏低约5~10 mAh·g-1,首次效率也偏低4%左右;在快速放电15C倍率下,使用涂碳铝箔的电芯比使用普通铝箔容量提高约15%左右,10C放电倍率下,平台增加0.3~0.4 V;使用涂碳铝箔电芯的常温自放电率较高,但容量恢复率也较高;550周循环下,使用涂碳铝箔可以使得电池的循环性能提高约1%。而在电池低温性能方面,使用涂碳铝箔对低温性能并无改善。     

Trace and surface analysis of ceramic layers of solid oxide fuel cells by mass spectrometry

For the trace analysis of impurities in thick ceramic layers of a solid oxide fuel cell (SOFC) sensitive solid-state mass spectrometric methods, such as laser ablation inductively coupled plasma mass spectrometry (LA-ICP-MS) and radiofrequency glow discharge mass spectrometry (rf-GDMS) have been developed and used. In order to quantify the analytical results of LA-ICP-MS, the relative sensitivity coefficients of elements in a La_0.6Sr_0.35MnO₃ matrix have been determined using synthetic standards. Secondary ion mass spectrometry (SIMS) – as a surface analytical method – has been used to characterize the element distribution and diffusion profiles of matrix elements on the interface of a perovskite/Y-stabilized ZrO₂ layer. The application of different mass spectrometric methods for process control in the preparation of ceramic layers for the SOFC is described.     

Surface analysis of sol-gel coatings on glass by secondary neutral mass spectrometry

Secondary neutral mass spectrometry (SNMS) has been used to profile coatings of the systems SiO₂ and 65SiO₂.20TiO₂.15ZrO₂ (STZ). The coatings have been deposited on float glass and heat insulating glass by dip coating from alkoxide solutions. The microporous gel coatings have been densified by heat treatment. The SBM method (separate bombardment mode) has been applied to characterize the systems and the HFM method (high frequency mode) to check for matrix effects in the SBM depth profiles. Both methods show sodium diffusion from the float glass substrate into the STZ coating and no significant sodium diffusion into the SiO₂ coating. Measurements of the coatings on the heat insulating glass indicate that the SnO₂ interlayer acts as a diffusion barrier. The diffusion of sodium from the float glass substrate into the STZ coating during consolidation has been analyzed by SBM-SNMS. The sputtering rate decreases with increasing consolidation. Due to large differences between sputtering rates of the substrate and of the microporous coatings, the calibration of sodium intensities from time to depth at the interface has not been possible. However, a correlation between the final temperature of heat treatment and the depth of the Na₂O depletion in the substrate surface under the coating can be obtained.     

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.