Structural Effects of 3D Inkjet-Printed Ni(O)-YSZ Pillared Electrodes on Performances of Solid Oxide Electrochemical Reactors

Increasing densities of reaction sites for gaseous reactants in solid oxide electrochemical reactors (SOERs), is a key strategy for achieving enhanced performance in either fuel cell or electrolysis modes. Fabrication of 3D structured components in SOERs can enhance those densities of reaction sites, which is achieved by 3D inkjet printing with high reproducibility, having developed inks with appropriate properties. First, the effects of pillar geometries on SOER performances are predicted through numerical simulations, enabling subsequent 3D printing to focus on the more effective geometries. Herein, the study reports the results of experimental validation of those predictions by evaluating the electrochemical performances of cells with various heights of 3D inkjet-printed Ni(O)- yttria stabilized zirconia (YSZ) pillars and YSZ pillars. Those measurements prove that increasing pillar heights generally increases SOER peak power densities in fuel cell mode and increased current densities at the thermoneutral potential (1.285 V) in steam electrolysis mode, as predicted by simulations. With increasing pillar heights, more limitations in performance enhancement are found with YSZ electrolyte pillars than with Ni-YSZ pillars, again as predicted by simulations. The subsequent microstructural analysis of Ni-YSZ pillars proves the suitability of the Ni(O)-YSZ composite particle ink formulation and the reliability of 3D printing.

Thermally Stable Silver Cathode Covered by Samaria-Doped Ceria for Low-Temperature Solid Oxide Fuel Cells

Samaria-doped ceria (SDC) overlayers were deposited on Ag cathodes by sputtering. The SDC sputtering time was varied to investigate the properties of the Ag-SDC overlayer cathode-coated fuel cells depending on the thickness of the SDC overlayers. Among the fabricated fuel cells, Ag with a 10-nm-thick SDC overlayer (Ag-SDC10) cathode-coated fuel cell exhibited the highest peak power density of 6.587 mW/cm2 at 450 °C, showing higher performance than a pristine Pt-coated fuel cell. Moreover, electrochemical impedance spectroscopy revealed that the Ag-SDC10 cathode-coated fuel cell significantly mitigated polarization loss originating from enhanced oxygen reduction reaction kinetics compared to the pristine Ag-coated fuel cell.

A High-Strength Solid Oxide Fuel Cell Supported by an Ordered Porous Cathode Membrane

The phase inversion tape casting has been widely used to fabricate open straight porous supports for solid oxide fuel cells (SOFCs), which can offer better gas transmission and minimize the concentration polarization. However, the overall weak strength of the macro-porous structure still limits the applications of these SOFCs. In this work, a novel SOFC supported by an ordered porous cathode membrane with a four-layer configuration containing a finger-like porous 3 mol% yttria- stabilized zirconia (3YSZ)-La0.8Sr0.2Co0.6Fe0.4O3-δ (LSCF) catalyst, porous 8 mol% yttria-stabilized zirconia (8YSZ)-LSCF catalyst, and dense 8YSZ porous 8YSZ-NiO catalyst is successfully prepared by the phase inversion tape casting, dip-coating, co-sintering, and impregnation process. The flexural strength of the open straight porous 3YSZ membrane is as high as 131.95 MPa, which meets the requirement for SOFCs. The cathode-supported single cell shows a peak power density of 540 mW cm-2 at 850 °C using H2 as the fuel. The degradation mechanism of the SOFC is investigated by the combination of microstructure characterization and distribution of relaxation times (DRT) analysis.

Novel Perovskite Structured Nd0.5Ba0.5Co1/3Ni1/3Mn1/3O3-δ as Highly Efficient Catalyst for Oxygen Electrode in Solid Oxide Electrochemical Cells

Developing catalytic materials with highly efficient oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) is essential for lower-temperature solid oxide fuel cell (SOFC) and electrolysis cell (SOEC) technologies. In this work, a novel triple perovskite material, Nd0.5Ba0.5Co1/3Ni1/3Mn1/3O3-δ, has been developed and employed as a catalyst for both ORR and OER in SOFC and SOEC operations at relatively lower temperatures, showing a low polarization resistance of 0.327 Ω cm2, high-power output of SOFC up to 773 mW cm-2 at 650 °C, and a high current density of 1.57 A cm-2 from SOEC operation at 1.5 V at 600 °C. The relaxation time distribution reveals that Nd0.5Ba0.5Co1/3Ni1/3Mn1/3O3-δ could maintain a slow polarization process at the relatively low operating temperature, offering a significant antipolarization advantage over other perovskite electrode materials. The Nd0.5Ba0.5Co1/3Ni1/3Mn1/3O3-δ electrode provides a low energy barrier of about 0.36 eV in oxygen ion mobility, which is beneficent for oxygen reduction/evolution reaction processes.

Heuristic Approach to Predict the Performance Degradation of a Solid Oxide Fuel Cell Cathode

The present work aims to predict the degradation in the performance of a solid oxide fuel cell (SOFC) cathode owing to cation interdiffusion between the electrolyte and cathode and surface segregation. Cation migration in the (La0.60Sr0.40)0.95Co0.20Fe0.80O3-x (LSCF)-Gd0.10Ce0.90O1.95 (GDC) composite cathode is evaluated in relation to time up to 1000 h using scanning transmission electron microscopy (STEM)-energy-dispersive X-ray spectroscopy (EDXS). The resulting insulating phase formed within the GDC interlayer is quantified by means of the volume fraction using a two-dimensional (2D) image analysis technique. For the very first time, the amount of the insulating phase in the GDC interlayer is quantified, and the corresponding performance degradation of the LSCF cathode is predicted. Mathematical relationships are established for the estimation of degradation due to surface segregation of the cathode. The ohmic resistance between the cathode and the GDC interlayer/electrolyte interface and the polarization resistance of the cathode, characterized by electrochemical impedance spectroscopy (EIS), show an excellent match with the predicted results. The combined degradation analysis and modeling for the cathode lifetime prediction provide a systematic understanding of the time-dependent cation migration and segregation behavior.

High-Performance (Ce, Zr)O2-Free Solid Oxide Fuel Cell with an Active-Sintered Cathode Interface and a Low-Temperature Densified Micron-Scale Barrier Layer

Incorporating a dense GDC (Gd0.1Ce0.9O1.95) barrier layer is an effective strategy to avoid harmful reactions between the LSCF (La0.6Sr0.4Co0.2Fe0.8O3-δ) cathode and the YSZ (yttria-stabilized zirconia) electrolyte. In this study, a micron-scale and dense GDC barrier layer is obtained by the combination of spin coating, low-temperature sintering, and hydrothermal-assisted densification. The cell exhibits decent output performance, with a peak power density of 1.07 W/cm2 at 780 °C. The ohmic and polarization resistances are significantly decreased by ∼44 and ∼36% than the cell with the screen-printed GDC barrier layer, respectively. Due to the low sintering temperature of the GDC barrier layer at 1200 °C, there is nearly no generation of (Ce, Zr)O2 at the interface of GDC/YSZ. The thin and dense GDC barrier layer effectively shortens the oxygen-ion conduction pathway, as well as hinders Sr migration from the cathode, highlighting its remarkable potential for industrial applications.

Ultralow Loading of Ru as a Bifunctional Catalyst for the Oxygen Electrode of Solid Oxide Cells

The oxygen evolution reaction (OER) is a significant contributor to the cell overpotential in solid oxide electrolyzer cells (SOECs). Although noble metals such as Ru and Ir have been utilized as OER catalysts, their widespread application in SOECs is hindered by their high cost and limited availability. In this study, we present a highly effective approach to enhance air electrode performance and durability by depositing an ultrathin layer of metallic Ru, as thin as ∼7.5 Å, onto (La0.6Sr0.4)0.95Co0.2Fe0.8O3-δ (LSCF) using plasma-enhanced atomic layer deposition (PEALD). Our study suggests that the emergence of a perovskite, SrRuO3, resulting from the reaction between PEALD-based Ru and surface-segregated Sr species, plays a crucial role in suppressing Sr segregation and maintaining favorable oxygen desorption kinetics, which ultimately improves the OER durability. Further, the PEALD Ru coating on LSCF also reduces the resistance to the oxygen reduction reaction (ORR), highlighting the bifunctional electrocatalytic activities for reversible fuel cells. When the LSCF electrode of a test cell is decorated with ∼7.5 Å of the Ru overcoat, a current density of 656 mA cm-2 at 1.3 V in electrolysis mode and a peak power density of 803 mW cm-2 in fuel cell mode are demonstrated at 700 °C, corresponding to an enhancement of 49.1 and 31.9%, respectively, compared to the pristine cell.

Theoretical Investigation of the Electrochemical Oxidation of H2 and CO Fuels on a Ruddlesden-Popper SrLaFeO4-δ Anode

The electrochemical oxidation of H₂ and CO fuels have been investigated on the Ruddlesden-Popper layered perovskite SrLaFeO_4-δ (SLF) under anodic solid oxide fuel cell conditions using periodic density functional theory and microkinetic modeling techniques. Two distinct FeO₂-plane-terminated surface models differing in terms of the underlying rock salt layer (SrO or LaO) are used to identify the active site and limiting factors for the electro-oxidation of H₂, CO, and syngas fuels. Microkinetic modeling predicted an order of magnitude higher turnover frequency for the electro-oxidation of H₂ compared to CO for SLF at short-circuit conditions. The surface model with an underlying SrO layer was found to be more active with respect to H₂ oxidation than the LaO-based surface model. At an operating voltage of less than 0.7 V, surface H₂O/CO₂ formation was found to be the key rate-limiting step, and the surface H₂O/CO₂ desorption was the key charge transfer step. In contrast, the bulk oxygen migration process was found to affect the overall rate at high cell voltage conditions above 0.9 V. In the presence of syngas fuel, the overall electrochemical activity is derived mainly from H₂ electro-oxidation and CO₂ is chemically shifted to CO via the reverse water-gas shift reaction. Substitutional doping of a surface Fe atom with Co, Ni, and Mn revealed that the H₂ electro-oxidation activity of FeO₂-plane terminated anodes with an underlying LaO rock salt layer can be improved with dopant introduction, with Co yielding a three orders of magnitude higher activity relative to the undoped LaO surface model. Constrained ab initio thermodynamic analysis furthermore suggested that the SLF anodes are resistant toward sulfur poisoning both in the presence and absence of dopants. Our findings reflect the role of various elements in controlling the fuel oxidation activity of SLF anodes that could aid the development of new Ruddlesden-Popper phase materials for fuel cell applications.

Solid Oxide Fuel Cells with Magnetron Sputtered Single-Layer SDC and Multilayer SDC/YSZ/SDC Electrolytes

Samarium-doped ceria (SDC) is considered as an alternative electrolyte material for intermediate-temperature solid oxide fuel cells (IT-SOFCs) because its conductivity is higher than that of commonly used yttria-stabilized zirconia (YSZ). The paper compares the properties of anode-supported SOFCs with magnetron sputtered single-layer SDC and multilayer SDC/YSZ/SDC thin-film electrolyte, with the YSZ blocking layer 0.5, 1, and 1.5 μm thick. The thickness of the upper and lower SDC layers of the multilayer electrolyte are constant and amount to 3 and 1 μm, respectively. The thickness of single-layer SDC electrolyte is 5.5 μm. The SOFC performance is studied by measuring current-voltage characteristics and impedance spectra in the range of 500-800 °C. X-ray diffraction and scanning electron microscopy are used to investigate the structure of the deposited electrolyte and other fuel cell layers. SOFCs with the single-layer SDC electrolyte show the best performance at 650 °C. At this temperature, open circuit voltage and maximum power density are 0.8 V and 651 mW/cm², respectively. The formation of the SDC electrolyte with the YSZ blocking layer improves the open circuit voltage up to 1.1 V and increases the maximum power density at the temperatures over 600 °C. It is shown that the optimal thickness of the YSZ blocking layer is 1 µm. The fuel cell with the multilayer SDC/YSZ/SDC electrolyte, with the layer thicknesses of 3/1/1 µm, has the maximum power density of 2263 and 1132 mW/cm² at 800 and 650 °C, respectively.

Highly Conductive Fe-Doped (La,Sr)(Ga,Mg)O3-δ Solid-State Membranes for Electrochemical Application

Membranes based on complex solid oxides with oxygen-ionic conductivity are widely used in high-temperature electrochemical devices such as fuel cells, electrolyzers, sensors, gas purifiers, etc. The performance of these devices depends on the oxygen-ionic conductivity value of the membrane. Highly conductive complex oxides with the overall composition of (La,Sr)(Ga,Mg)O₃ have regained the attention of researchers in recent years due to the progress in the development of electrochemical devices with symmetrical electrodes. In this research, we studied how the introduction of iron cations into the gallium sublattice in (La,Sr)(Ga,Mg)O₃ affects the fundamental properties of the oxides and the electrochemical performance of cells based on (La,Sr)(Ga,Fe,Mg)O₃. It was found that the introduction of iron leads to an increase in the electrical conductivity and thermal expansion in an oxidizing atmosphere, while no such behavior was observed in a wet hydrogen atmosphere. The introduction of iron into a (La,Sr)(Ga,Mg)O₃ electrolyte leads to an increase in the electrochemical activity of Sr₂Fe_1.5Mo_0.5O_6-δ electrodes in contact with the electrolyte. Fuel cell studies have shown that, in the case of a 550 µm-thick Fe-doped (La,Sr)(Ga,Mg)O₃ supporting electrolyte (Fe content 10 mol.%) and symmetrical Sr₂Fe_1.5Mo_0.5O_6-δ electrodes, the cell exhibits a power density of more than 600 mW/cm² at 800 °C.

Thermo-Electro-Chemo-Mechanical Coupled Modeling of Solid Oxide Fuel Cell with LSCF-GDC Composite Cathode

Intricate relationships between transport phenomena, reaction mechanisms, and mechanical aspects likely affect the durability of solid oxide fuel cell (SOFC) stack. This study presents a modeling framework that combines thermo-electro-chemo models (including the methanol conversion process and the electrochemical reactions of the carbon monoxide as well as the hydrogen) and a contact thermo-mechanical model that considers the effective mechanical properties of composite electrode material. Detailed parametric studies are performed focusing on the inlet fuel species (hydrogen, methanol syngas) and flow arrangements (co-flow, counter-flow) under typical operating conditions (operating voltage 0.7 V), and performance indicators of the cell, such as the high-temperature zone, current density, and maximum thermal stress were discussed for parameter optimization. The simulated results show that the high temperature zone of the hydrogen-fueled SOFC is located at the central part of units 5, 6, and 7, and the maximum value is about 40 K higher than that of methanol syngas-fueled SOFC. The charge transfer reactions can occur throughout the cathode layer. The counter-flow improves the trend of the current density distribution of hydrogen-fueled SOFC, while the effect on the current density distribution of methanol syngas-fueled SOFC is small. The distribution characteristics of the stress field within SOFC are extremely complex, and the inhomogeneity of the stress field distribution can be effectively improved by feeding methanol syngas. The counter-flow improves the stress distribution state of the electrolyte layer of methanol syngas-fueled SOFC, and the maximum tensile stress value is reduced by about 37.7%.

Novel n-i CeO2/a-Al2O3 Heterostructure Electrolyte Derived from the Insulator a-Al2O3 for Fuel Cells

Heterostructure technologies have been regarded as promising methods in the development of electrolytes with high ionic conductivity for low-temperature solid oxide fuel cells (LT-SOFCs). Here, a novel semiconductor/insulator (n-i) heterostructure strategy has been proposed to develop composite electrolytes for LT-SOFCs based on CeO₂ and the insulator amorphous alumina (a-Al₂O₃). The constructed CeO₂/a-Al₂O₃ electrolyte exhibits an ionic conductivity of up to 0.127 S cm^-1, and its fuel cell achieves a maximum power density (MPD) of 1017 mW cm^-2 with an open-circuit voltage (OCV) of 1.14 V at 550 °C without the short-circuiting problem, suggesting that the introduction of a-Al₂O₃ can effectively suppress the electron conduction of CeO₂. It is found that the potential energy barrier at the heterointerfaces caused by the ultrawide band gap of the insulator a-Al₂O₃ plays an important role in restraining electron conduction. Simultaneously, the thermoelectric effect of the insulator induces more oxygen vacancies because of interface charge compensation, which further promotes ionic transport and results in high ionic conductivity and fuel cell performance. This study presents a practical n-i heterostructure electrolyte design, and further research confirmed the advanced functionality of the CeO₂/a-Al₂O₃ electrolyte. Our study may open frontiers in the field of developing high-efficiency electrolytes of LT-SOFCs using insulating materials such as amorphous alumina.

Ni/NiO Exsolved Perovskite La0.2Sr0.7Ti0.9Ni0.1O3-δ for Semiconductor-Ionic Fuel Cells: Roles of Electrocatalytic Activity and Physical Junctions

A semiconductor-ionic fuel cell (SIFC) is recognized as a promising technology and an alternative approach to reduce the operating temperature of solid oxide fuel cells. The development of alternative semiconductors substituting easily reduced transition metal oxide is a great challenge as high activity and durability should be satisfied simultaneously. In this study, the B-site Ni-doped La_0.2Sr_0.7Ti_0.9Ni_0.1O_3-δ (LSTN) perovskite is synthesized and used as a potential semiconductor for SIFC. The in situ exsolution and A-site deficiency strategy enable the homogeneous decoration of Ni/NiO nanoparticles as reactive sites to improve the electrode reaction kinetics. It also supports the formation of basic ingredient of the Schottky junction to improve the charge separation efficiency. Furthermore, additional symmetric Ni_0.8Co_0.15Al_0.05LiO_2-δ (NCAL) electrocatalytic electrode layers significantly enhance the electrode reaction activity and cells' charge separation efficiency, as confirmed by the superior open circuit voltage of 1.13 V (close to Nernst's theoretical value) and peak power density of 650 mW cm^-2 at 550 °C, where the latter is one order of magnitude higher than NCAL electrode-free SIFC. Additionally, a bulk heterojunction effect is proposed to illustrate the electron-blocking and ion-promoting processes of the semiconductor-ionic composite electrolyte in SIFCs, based on the energy band values of the applied materials. Overall, we found that the energy conversion efficiency of novel SIFC can be remarkably improved through in situ exsolution and intentional introduction of the catalytic functionality.

Advanced Proton-Conducting Ceramics Based on Layered Perovskite BaLaInO4 for Energy Conversion Technologies and Devices

Production of high efficiency renewable energy source for sustainable global development is an important challenge for humans. Hydrogen energy systems are one of the key elements for the development of sustainable energy future. These systems are eco-friendly and include devices such as protonic ceramic fuel cells, which require advanced proton-conducting materials. In this study, we focused on new ceramics with significantly improved target properties for hydrogen energy purposes. Neodymium-doped phase based on layered perovskite BaLaInO₄ was obtained for the first time. The ability for water intercalation and proton transport was proved. It was shown that the composition BaLa_0.9Nd_0.1InO₄ is the predominant proton conductor below 400 °C under wet air. Moreover, isovalent doping of layered perovskites AA'BO₄ is the promising method for improving transport properties and obtaining novel advanced proton-conducting ceramic materials.

Synergistically Promoting Coking Resistance of a La0.4Sr0.4Ti0.85Ni0.15O3-δ Anode by Ru-Doping-Induced Active Twin Defects and Highly Dispersed Ni Nanoparticles

The development of anodes with highly efficient electrochemical catalysis and good durability is crucial for solid oxide fuel cells (SOFCs). This paper reports a superior Ru-doped La_0.4Sr_0.4Ti_0.85Ni_0.15O_3-δ (L0.4STN) anode material with excellent catalytic activity and good stability. The doping of Ru can inhibit the agglomeration of in situ-exsolved Ni nanoparticles on the surface and induce the formation of abundant multiple-twinned defects in the perovskite matrix, which significantly increase the concentration of oxygen vacancies. The reduced L0.4STRN (R-L0.4STRN) anode shows an area-specific resistance (ASR) of 0.067 Ω cm² at 800 °C, which is only about one-third of that of stochiometric R-L0.6STN (0.212 Ω cm²). A single cell with the R-L0.4STRN anode shows excellent stability (∼50 h at 650 °C) in both H₂ and CH₄. Furthermore, R-L0.4STRN exhibits outstanding resistance to carbon deposition, which can be attributed to the synergistic effect of highly dispersed Ni nanoparticles and active twinned defects induced by Ru doping.

Synthesis and Evaluation of LaBaCo2-xMoxO5+δ Cathode for Intermediate-Temperature Solid Oxide Fuel Cells

LaBaCo_2-xMo_xO_5+δ (LBCMx, x = 0-0.08) cathodes synthesized by a sol-gel method were evaluated for intermediate-temperature solid oxide fuel cells. The limit of the solid solubility of Mo in LBCMx was lower than 0.08. As the content of Mo increased gradually from 0 to 0.06, the thermal expansion coefficient decreased from 20.87 × 10^-6 K^-1 to 18.47 × 10^-6 K^-1. The introduction of Mo could increase the conductivity of LBCMx, which varied from 464 S cm^-1 to 621 S cm^-1 at 800 °C. The polarization resistance of the optimal cathode LBCM0.04 in air at 800 °C was 0.036 Ω cm², reduced by a factor of 1.67 when compared with the undoped Mo cathode. The corresponding maximum power density of a single cell based on a YSZ electrolyte improved from 165 mW cm^-2 to 248 mW cm^-2 at 800 °C.

Facile Approach to Enhance Activity and CO2 Resistance of a Novel Cobalt-Free Perovskite Cathode for Solid Oxide Fuel Cells

Developing high-performance and cost-effective cathodes is ever-increasingly vital for the advancement of intermediate-temperature solid oxide fuel cells (IT-SOFCs). To facilitate the popularization of nonprecious metallic and cobalt-free oxygen reduction electrodes, herein, we propose a novel perovskite-based BaFeO_3-δ (BF) matrix, Ba_0.75Sr_0.25Fe_0.875Y_0.125O_3-δ (BSFY), as a highly active cathode for IT-SOFCs. To our satisfaction, the BSFY electrode showcases a low area-specific resistance of 0.063 Ω cm², as well as a high peak power density of 1288 mW cm^-2 at 600 °C, yielding a more than threefold improvement compared to that of its BF counterpart (371 mW cm^-2). The long-term durability test highlights its practicability under the IT operating condition. When tested in 10 vol % CO₂-containing air, the BSFY electrode exhibits impressive resistance against contaminants within 50 h (<0.4 Ω cm² with a deterioration rate of ∼0.00011 Ω cm² min^-1). Coupled with its reversible response between pure air and the contaminant, the BSFY cathode is expected to be a promising cobalt-free alternative with high CO₂ resistance for IT-SOFCs.

Plasmochemical Modification of Crofer 22APU for Intermediate-Temperature Solid Oxide Fuel Cell Interconnects Using RF PA CVD Method

The results of plasmochemical modification on Crofer 22APU ferritic stainless steel with a SiC_xN_y:H layer, as well as the impact of these processes on the increase in usability of the steel as intermediate-temperature solid oxide fuel cell (IT-SOFC), interconnects, are presented in this work. The layer was obtained using Radio-Frequency Plasma-Activated Chemical Vapor Deposition (RF PA CVD, 13.56 MHz) with or without the N⁺ ion modification process of the steel surface. To determine the impact of the surface modification on the steel's resistance to high-temperature corrosion and on its mechanical properties, the chemical composition, atomic structure, and microstructure were investigated by means of IR spectroscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Microhardness, Young's modulus, wear rate, as well as electrical resistance, were also determined. Micromechanical experiments showed that the plasmochemical modification has a positive influence on the surface hardness and Young's modulus of the investigated samples. High-temperature oxidation studies performed for the samples indicate that N⁺ ion modification prior to the deposition of the SiC_xN_y:H layer improves the corrosion resistance of Crofer 22APU steel modified via CVD. The area-specific resistance of the studied samples was 0.01 Ω·cm², which is lower than that of bare steel after 500 h of oxidation at 1073 K. It was demonstrated that the deposition of the SiC_xN_y:H layer preceded by N⁺ ion modification yields the best properties.

Layering Optimization of the SrFe0.9Ti0.1O3-δ-Ce0.8Sm0.2O1.9 Composite Cathode

Cathode thickness plays a major role in establishing an active area for an oxygen reduction reaction in energy converter devices, such as solid oxide fuel cells. In this work, we prepared SrFe_0.9Ti_0.1O_3−δ–Ce_0.8Sm_0.2O_1.9 composite cathodes with different layers (1×, 3×, 5×, 7×, and 9× layer). The microstructural and electrochemical performance of each cell was then explored through scanning electron microscopy and electrochemical impedance spectroscopy (EIS). EIS analysis showed that the area-specific resistance (ASR) decreased from 0.65 Ωcm² to 0.12 Ωcm² with the increase in the number of layers from a 1× to a 7×. However, the ASR started to slightly increase at the 9× layer to 2.95 Ωcm² due to a higher loss of electrode polarization resulting from insufficient gas diffusion and transport. Therefore, increasing the number of cathode layers could increase the performance of the cathode by enlarging the active area for the reaction up to the threshold point.

A Review of X-ray Photoelectron Spectroscopy Technique to Analyze the Stability and Degradation Mechanism of Solid Oxide Fuel Cell Cathode Materials

Nondestructive characterization of solid oxide fuel cell (SOFC) materials has drawn attention owing to the advances in instrumentation that enable in situ characterization during high-temperature cell operation. X-ray photoelectron spectroscopy (XPS) is widely used to investigate the surface of SOFC cathode materials because of its excellent chemical specificity and surface sensitivity. The XPS can be used to analyze the elemental composition and oxidation state of cathode layers from the surface to a depth of approximately 5–10 nm. Any change in the chemical state of the SOFC cathode at the surface affects the migration of oxygen ions to the cathode/electrolyte interface via the cathode layer and causes performance degradation. The objective of this article is to provide a comprehensive review of the adoption of XPS for the characterization of SOFC cathode materials to understand its degradation mechanism in absolute terms. The use of XPS to confirm the chemical stability at the interface and the enrichment of cations on the surface is reviewed. Finally, the strategies adopted to improve the structural stability and electrochemical performance of the LSCF cathode are also discussed.

Classification of Solid Oxide Fuel Cells

Solid oxide fuel cells (SOFC) are promising, environmentally friendly energy sources. Many works are devoted to the study of materials, individual aspects of SOFC operation, and the development of devices based on them. However, there is no work covering the entire spectrum of SOFC concepts and designs. In the present review, an attempt is made to collect and structure all types of SOFC that exist today. Structural features of each type of SOFC have been described, and their advantages and disadvantages have been identified. A comparison of the designs showed that among the well-studied dual-chamber SOFC with oxygen-ion conducting electrolyte, the anode-supported design is the most suitable for operation at temperatures below 800 °C. Other SOFC types that are promising for low-temperature operation are SOFC with proton-conducting electrolyte and electrolyte-free fuel cells. However, these recently developed technologies are still far from commercialization and require further research and development.

Influence of Deposition Modes and Thermal Annealing on Residual Stresses in Magnetron-Sputtered YSZ Membranes

Thin-film electrolyte made of 8-mol% yttria stabilized zirconia (8YSZ) for solid oxide fuel cells (SOFCs) was fabricated on anode substrates using reactive magnetron sputtering of Zr-Y targets in a mixture of Ar and O2 gases. The deposition of 4−6 µm thin-film electrolyte was in the transition or oxide modes differing by the oxygen concentration in the sputtering atmosphere. The half-cell bending of the anode-supported SOFCs was measured to determine the residual stresses in the electrolyte films after the deposition and thermal annealing in air. The dependences were studied between the deposition modes, residual stresses in the films, and the SOFC performance. At 800 °C, the maximum power density of SOFCs ranged between 0.58 and 1.2 W/cm2 depending on the electrolyte deposition mode. Scanning electron microscopy was carried out to investigate the surface morphology and structure of the YSZ electrolyte films after thermal annealing. Additionally, an X-ray diffraction analysis of the YSZ electrolyte films was conducted for the synchrotron radiation beam during thermal annealing at different temperatures up to 1300 °C. It was found that certain deposition modes provide the formation of the YSZ electrolyte films with acceptable residual stresses (<1 GPa) at room temperature, including films deposited on large area anodes (100 × 100 mm2).

Improvement of La0.8Sr0.2MnO3-δ Cathode Material for Solid Oxide Fuel Cells by Addition of YFe0.5Co0.5O3

The high efficiency of solid oxide fuel cells with La_0.8Sr_0.2MnO_3−δ (LSM) cathodes working in the range of 800–1000 °C, rapidly decreases below 800 °C. The goal of this study is to improve the properties of LSM cathodes working in the range of 500–800 °C by the addition of YFe_0.5Co_0.5O₃ (YFC). Monophasic YFC is synthesized and sintered at 950 °C. Composite cathodes are prepared on Ce_0.8Sm_0.2O_1.9 electrolyte disks using pastes containing YFC and LSM powders mixed in 0:1, 1:19, and 1:1 weight ratios denoted LSM, LSM1, and LSM1, respectively. X-ray diffraction patterns of tested composites reveal the presence of pure perovskite phases in samples sintered at 950 °C and the presence of Sr₄Fe₄O₁₁, YMnO₃, and La_0.775Sr_0.225MnO_3.047 phases in samples sintered at 1100 °C. Electrochemical impedance spectroscopy reveals that polarization resistance increases from LSM1, by LSM, to LSM2. Differences in polarization resistance increase with decreasing operating temperatures because activation energy rises in the same order and equals to 1.33, 1.34, and 1.58 eV for LSM1, LSM, and LSM2, respectively. The lower polarization resistance of LSM1 electrodes is caused by the lower resistance associated with the charge transfer process.

Development of Ni-Sr(V,Ti)O3-δ Fuel Electrodes for Solid Oxide Fuel Cells

A series of strontium titanates-vanadates (STVN) with nominal cation composition Sr_1-xTi_1-y-zV_yNi_zO_3-δ (x = 0–0.04, y = 0.20–0.40 and z = 0.02–0.12) were prepared by a solid-state reaction route in 10% H₂–N₂ atmosphere and characterized under reducing conditions as potential fuel electrode materials for solid oxide fuel cells. Detailed phase evolution studies using XRD and SEM/EDS demonstrated that firing at temperatures as high as 1200 °C is required to eliminate undesirable secondary phases. Under such conditions, nickel tends to segregate as a metallic phase and is unlikely to incorporate into the perovskite lattice. Ceramic samples sintered at 1500 °C exhibited temperature-activated electrical conductivity that showed a weak p(O₂) dependence and increased with vanadium content, reaching a maximum of ~17 S/cm at 1000 °C. STVN ceramics showed moderate thermal expansion coefficients (12.5–14.3 ppm/K at 25–1100 °C) compatible with that of yttria-stabilized zirconia (8YSZ). Porous STVN electrodes on 8YSZ solid electrolytes were fabricated at 1100 °C and studied using electrochemical impedance spectroscopy at 700–900 °C in an atmosphere of diluted humidified H₂ under zero DC conditions. As-prepared STVN electrodes demonstrated comparatively poor electrochemical performance, which was attributed to insufficient intrinsic electrocatalytic activity and agglomeration of metallic nickel during the high-temperature synthetic procedure. Incorporation of an oxygen-ion-conducting Ce_0.9Gd_0.1O_2-δ phase (20–30 wt.%) and nano-sized Ni as electrocatalyst (≥1 wt.%) into the porous electrode structure via infiltration resulted in a substantial improvement in electrochemical activity and reduction of electrode polarization resistance by 6–8 times at 900 °C and ≥ one order of magnitude at 800 °C.

Theoretical and Experimental Investigations on K-doped SrCo0.9 Nb0.1 O3-δ as a Promising Cathode for Proton-Conducting Solid Oxide Fuel Cells

Improving proton conduction in cathodes is regarded as one of the most effective methods to accelerate the sluggish proton-involved oxygen reduction reaction (P-ORR) for proton-conducting solid oxide fuel cells (P-SOFCs). In this work, K⁺ dopant was used to improve the proton uptake and migration ability of SrCo_0.9 Nb_0.1 O_3-δ (SCN). K⁺ -doped SCN (KSCN) demonstrated great potential to be a promising cathode for P-SOFCs. Density functional theory calculations suggested that doping with K⁺ led to more oxygen vacancies and more negative values of hydration enthalpy, which was helpful for the improvement of proton concentration. Importantly, the proton migration barriers could be depressed, benefiting proton conduction. Electrochemical investigations signified that the cell using KSCN cathode had a peak power density of 967 mW cm^-2 at 700 °C, about 54.1 % higher than that using a SCN cathode. This research highlights the K⁺ -doping strategy to improve electrochemical performance of cathodes for P-SOFCs.

Exsolution of Ni Nanoparticles from A-Site-Deficient Layered Double Perovskites for Dry Reforming of Methane and as an Anode Material for a Solid Oxide Fuel Cell

Exsolution is a promising technique to design metal nanoparticles for electrocatalysis and renewable energy. In this work, Ni-doped perovskites, (Pr_0.5Ba_0.5)_1-x/2Mn_1-x/2Ni_x/2O_3-δ with x = 0, 0.05, 0.1, and 0.2 (S-PBMNx), were prepared to design exsolution systems as solid oxide fuel cell anodes and for catalysis applications. X-ray diffraction and transmission electron microscopy (TEM) analyses demonstrated that correlating A-site deficiency with Ni content can effectively induce exsolution of all Ni under H₂ atmosphere at T ∼ 875 °C, yielding the reduced (exsolved) R-PBMNx materials. On heating the exsolution systems in air, metal incorporation in the oxide lattice did not occur; instead, the Ni nanoparticles oxidized to NiO on the layered perovskite surface. The lowest area-specific resistance (ASR) under wet 5% H₂/N₂ in symmetrical cells was observed for R-PBMN0.2 anode (ASR ∼ 0.64 Ω cm² at 850 °C) due to the highest Ni particle density in the R-PBMNx series. The best performance for dry reforming of methane (DRM) was also obtained for R-PBMN0.2, with CH₄ and CO₂ conversion rates at 11 and 32%, respectively, and the highest production of H₂ (37%). The DRM activity of R-PBMN0.2 starts at 800 °C and is sustained for up to at least 5 h operation with little carbon deposition (0.017 g·gcat^-1·h^-1). These results clearly demonstrate that varying Ni-doping in layered double perovskite oxides is an effective strategy to manipulate the electrochemical performance and catalytic activity for energy conversion purposes.

Effectively Promoting Activity and Stability of a MnCo2O4-Based Cathode by In Situ Constructed Heterointerfaces for Solid Oxide Fuel Cells

The development of multiphase composite electrocatalysts plays a key role in achieving the efficient and durable operation of intermediate-temperature solid oxide fuel cells (IT-SOFCs). Herein, a self-assembled nanocomposite is developed as the oxygen reduction reaction (ORR) catalyst for IT-SOFCs through a coprecipitation method. The nanocomposite is composed of a doped (Mn_0.6Mg_0.4)_0.8Sc_0.2Co₂O₄ (MMSCO) spinel oxide (84 wt %), an orthorhombic perovskite phase (11.3 wt %, the spontaneous combination of PrO₂ additives and spinel), and a minor Sc₂O₃ phase (4.7 wt %). The surface of the (Mn_0.6Mg_0.4)_0.8Sc_0.2Co₂O₄ phase is activated by the self-assembled nanocoating with many heterogeneous interfaces. Thence, the ORR kinetics is obviously accelerated and an area-specific resistance (ASR) of ∼0.11 Ω cm² is obtained at 750 °C. Moreover, a single cell with the cathode shows a peak power density (PPD) of 1144.1 mW cm^-2 at 750 °C, much higher than that of the cell with the MnCo₂O₄ cathode (456.2 mW cm^-2). An enhanced stability of ∼120 h (0.8 A cm^-2, 750 °C) is also achieved, related to the reduced thermal expansion coefficient (13.9 × 10^-6 K^-1). The improvement in ORR kinetics and stability can be attributed to the refinement of grains, the formation of heterointerfaces, and the enhancement of mechanical compatibility.

A Direct n-Butane Solid Oxide Fuel Cell Using Ba(Zr0.1Ce0.7Y0.1Yb0.1)0.9Ni0.05Ru0.05O3-δ Perovskite as the Reforming Layer

Hydrocarbon-fueled solid oxide fuel cells (SOFCs) that can operate in the intermediate temperature range of 500-700 °C represent an attractive SOFC device for combined heat and power applications in the industrial market. One of the ways to realize such a device relies upon exploiting an in situ steam reforming process in the anode catalyzed by an anti-carbon coking catalyst. Here, we report a new Ni and Ru bimetal-doped perovskite catalyst, Ba(Zr_0.1Ce_0.7Y_0.1Yb_0.1)_0.9Ni_0.05Ru_0.05O_3-δ (BZCYYbNRu), with enhanced catalytic hydrogen production activity on n-butane (C₄H₁₀), which can resist carbon coking over extended operation durations. Ru in the perovskite lattice inhibits Ni precipitation from perovskite, and the high water adsorption capacity of proton conducting perovskite improves the coking resistance of BZCYYbNRu. When BZCYYbNRu is used as a steam reforming catalyst layer on a Ni-YSZ-supported anode, the single fuel cell not only achieves a higher power density of 1113 mW cm^-2 at 700 °C under a 10 mL min^-1 C₄H₁₀ continuous feed stream at a steam to carbon (H₂O/C) ratio of 0.5 but also shows a much better operational stability for 100 h at 600 °C compared with those reported in the literature.

Hydrogen Oxidation Pathway Over Ni-Ceria Electrode: Combined Study of DFT and Experiment

Ni–ceria cermets are potential anodes for intermediate-temperature solid oxide fuel cells, thanks to the catalytic activity and mixed conductivities of ceria-based materials associated with the variable valence states of cerium. However, the anodic reaction mechanism in the Ni–ceria systems needs to be further revealed. Via density functional theory with strong correlated correction method, this work gains insight into reaction pathways of hydrogen oxidation on a model system of Ni₁₀-CeO₂(111). The calculation shows that electrons tend to be transferred from Ni₁₀ cluster to cerium surface, creating surface oxygen vacancies. Six pathways are proposed considering different adsorption sites, and the interface pathway proceeding with hydrogen spillover is found to be the prevailing process, which includes a high adsorption energy of −1.859 eV and an energy barrier of 0.885 eV. The density functional theory (DFT) calculation results are verified through experimental measurements including electrical conductivity relaxation and temperature programmed desorption. The contribution of interface reaction to the total hydrogen oxidation reaction reaches up to 98%, and the formation of Ni–ceria interface by infiltrating Ni to porous ceria improves the electrochemical activity by 72% at 800°C.

Infiltrated Ni0.08Co0.02CeO2-x@Ni0.8Co0.2 Catalysts for a Finger-Like Anode in Direct Methane-Fueled Solid Oxide Fuel Cells

Direct utilization of methane in solid oxide fuel cells (SOFCs) is greatly impeded by the grievous carbon deposition and the much depressed catalytic activity. In this work, a promising anode, taking finger-like porous YSZ as the anode substrate and impregnated Ni_0.08Co_0.02Ce_0.9O_2-δ@Ni_0.8Co_0.2O as the novel catalyst, is fabricated via the phase conversion-combined tape-casting technique. This anode shows commendable mechanical strength and excellent catalytic activity and stability toward the methane conversion reactions, which is attributed to the exsolved alloy nanoparticles and the active oxygen species on the reduced Ni_0.08Co_0.02Ce_0.9O_2-δ catalyst as well as the facilitated methane transport rooting in the special open-pore microstructure of the anode substrate. Strikingly, this button cell delivers an excellent peak power density of 730 mW cm^-2 at 800 °C in 97% CH₄/3% H₂O fuel, only 9% lower than that in 97% H₂/3% H₂O. Our work shed new light on the SOFC anode developments.

Mixed Ionic-Electronic Conductivity, Redox Behavior and Thermochemical Expansion of Mn-Substituted 5YSZ as an Interlayer Material for Reversible Solid Oxide Cells

Manganese-substituted 5 mol.% yttria-stabilized zirconia (5YSZ) was explored as a prospective material for protective interlayers between electrolyte and oxygen electrodes in reversible solid oxide fuel/electrolysis cells. [(ZrO₂)_0.95(Y₂O₃)_0.05]_1−x[MnO_y]_x (x = 0.05, 0.10 and 0.15) ceramics with cubic fluorite structure were sintered in air at 1600 °C. The characterization included X-ray diffraction (XRD), scanning electron microscopy (SEM)/energy dispersive spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), thermogravimetry and dilatometry in controlled atmospheres, electrical conductivity measurements, and determination of oxygen-ion transference numbers by the electromotive force (EMF) technique. Mn-substituted 5YSZ solid solutions exhibit variable oxygen nonstoichiometry with manganese cations in a mixed 2+/3+ oxidation state under oxidizing conditions. Substitution by manganese gradually increases the extent of oxygen content variation on thermal/redox cycling, chemical contribution to thermal expansion and dimensional changes on reduction. It also deteriorates oxygen-ionic conductivity and improves p-type electronic conductivity under oxidizing conditions, leading to a gradual transformation from predominantly ionic to prevailing electronic transport with increasing x. Mn^2+/3+→Mn²⁺ transformation under reducing atmospheres is accompanied by the suppression of electronic transport and an increase in ionic conductivity. All Mn-substituted 5YSZ ceramics are solid electrolytes under reducing conditions. Prolonged treatments in reducing atmospheres, however, promote microstructural changes at the surface of bulk ceramics and Mn exsolution. Mn-substituted 5YSZ with 0.05 ≤ x < 0.10 is considered the most suitable for the interlayer application, due to the best combination of relevant factors, including oxygen content variations, levels of ionic/electronic conductivity and thermochemical expansion.

Route to High-Performance Micro-solid Oxide Fuel Cells on Metallic Substrates

Micro-solid oxide fuel cells based on thin films have strong potential for use in portable power devices. However, devices based on silicon substrates typically involve thin-film metallic electrodes which are unstable at high temperatures. Devices based on bulk metal substrates overcome these limitations, though performance is hindered by the challenge of growing state-of-the-art epitaxial materials on metals. Here, we demonstrate for the first time the growth of epitaxial cathode materials on metal substrates (stainless steel) commercially supplied with epitaxial electrolyte layers (1.5 μm (Y₂O₃)_0.15(ZrO₂)_0.85 (YSZ) + 50 nm CeO₂). We create epitaxial mesoporous cathodes of (La_0.60Sr_0.40)_0.95Co_0.20Fe_0.80O₃ (LSCF) on the substrate by growing LSCF/MgO vertically aligned nanocomposite films by pulsed laser deposition, followed by selectively etching out the MgO. To enable valid comparison with the literature, the cathodes are also grown on single-crystal substrates, confirming state-of-the-art performance with an area specific resistance of 100 Ω cm² at 500 °C and activation energy down to 0.97 eV. The work marks an important step toward the commercialization of high-performance micro-solid oxide fuel cells for portable power applications.

Metal Exsolution to Enhance the Catalytic Activity of Electrodes in Solid Oxide Fuel Cells

Exsolution is a novel technology for attaching metal catalyst particles onto ceramic anodes in the solid oxide fuel cells (SOFCs). The exsolved metal particles in the anode exhibit unique properties for reaction and have demonstrated remarkable stabilities under conditions that normally lead to coking. Despite extensive investigations, the underlying principles behind exsolution are still under investigation. In this review, the present status of exsolution materials for SOFC applications is reported, including a description of the fundamental concepts behind metal incorporation in oxide lattices, a listing of proposed mechanisms and thermodynamics of the exsolution process and a discussion on the catalytic properties of the resulting materials. Prospects and opportunities to use materials produced by exsolution for SOFC are discussed.

Multiple Effects of Iron and Nickel Additives on the Properties of Proton Conducting Yttrium-Doped Barium Cerate-Zirconate Electrolytes for High-Performance Solid Oxide Fuel Cells

Transition metal oxides have been used as sintering aids for proton-conducting barium cerate-zirconates, which are promising electrolyte materials for low-temperature solid oxide fuel cells (SOFCs) and high-performance electrochemical membrane reactors. However, the effects of the additives on properties other than the density of the electrolytes have been ignored. Here, we report our findings that transition metal additives also affect the electrical properties, stability, and even catalytic activity of proton-conducting ABO₃-type perovskites. BaCe_0.7Zr_0.1Y_0.2O_3-δ (BCZY) is selected as the basic material, and 2 mol % of Ni_1-xFe_x (x range: from 0 to 1.0) oxides and 4 mol % of FeO_1.5 are, respectively, added into BCZY to prepare electrolytes of anode-supported SOFCs. All of the electrolytes with additives can be densified after sintering at 1400 °C for 5 h, while BCZY without additive is porous. X-ray diffraction (XRD) spectra show that Ni and Fe are doped into the lattice of BCZY. For the first time, we find a positive function of Fe additive in BCZY that it not only acts as a good sintering aid but also improves the electrical performance and stability of the BCZY electrolyte in CO₂ and H₂O at reduced temperatures. The cell with the 2 mol % Ni_0.5Fe_0.5-doped BCZY electrolyte, with an unoptimized cathode, gives a power density of 973 mW cm^-2 at 700 °C, 120 mW cm^-2 at 450 °C, and 45 mW cm^-2 at 350 °C. It operates under a constant current of 800 mA cm^-2 at 650 °C for over 200 h, during which the voltage decreases from 0.73 to 0.71 V. A newly discovered densified layer, formed in the cathode during the SOFC operation, may cause the degradation.

Bio-inspired gas sensing: boosting performance with sensor optimization guided by "machine learning"

The performance of existing gas sensors often degrades in field conditions because of the loss of measurement accuracy in the presence of interferences. Thus, new sensing approaches are required with improved sensor selectivity. We are developing a new generation of gas sensors, known as multivariable sensors, that have several independent responses for multi-gas detection with a single sensor. In this study, we analyze the capabilities of natural and fabricated photonic three-dimensional (3-D) nanostructures as sensors for the detection of different gaseous species, such as vapors and non-condensable gases. We employed bare Morpho butterfly wing scales to control their gas selectivity with different illumination angles. Next, we chemically functionalized Morpho butterfly wing scales with a fluorinated silane to boost the response of these nanostructures to the vapors of interest and to suppress the response to ambient humidity. Further, we followed our previously developed design rules for sensing nanostructures and fabricated bioinspired inorganic 3-D nanostructures to achieve functionality beyond natural Morpho scales. These fabricated nanostructures have embedded catalytically active gold nanoparticles to operate at high temperatures of ≈300 °C for the detection of gases for solid oxide fuel cell (SOFC) applications. Our performance advances in the detection of multiple gaseous species with specific nanostructure designs were achieved by coupling the spectral responses of these nanostructures with machine learning (a.k.a. multivariate analysis, chemometrics) tools. Our newly acquired knowledge from studies of these natural and fabricated inorganic nanostructures coupled with machine learning data analytics allowed us to advance our design rules for sensing nanostructures toward the required gas selectivity for numerous gas monitoring scenarios at room and high temperatures for industrial, environmental, and other applications.

Co3O4-Impregnated NiO-YSZ: An Efficient Catalyst for Direct Methane Electrooxidation

Co₃O₄-impregnated NiO-YSZ (yttria-stabilized zirconia) is a possible electrocatalyst for direct methane electrooxidation with both high catalytic activity and the ability to mitigate coking. The physical and electrochemical properties of Co₃O₄-impregnated NiO-YSZ anodes are investigated and benchmarked against NiO-YSZ and CeO₂-impregnated NiO-YSZ anodes. The following methane electrooxidation activity trend: Co₃O₄-impregnated NiO-YSZ > CeO₂-impregnated NiO-YSZ > NiO-YSZ with i_o (exchange current density) values of 88, 83, and 2 mA cm^-2, respectively, is obtained in the high overpotential region. The high activity of Co₃O₄-impregnated NiO-YSZ is attributed to the changes in the electronic structure and microstructure with the incorporation of nickel into the lattice of Co₃O₄ as observed using X-ray photoelectron spectroscopy, temperature-programmed reduction, high-resolution transmission electron microscopy, and field emission scanning electron microscopy. Co₃O₄-impregnated NiO-YSZ also demonstrated the least coking during operation, confirming its utility as a methane electrooxidation catalyst.

Nanostructured BaCo0.4Fe0.4Zr0.1Y0.1O3-δ Cathodes with Different Microstructural Architectures

Lowering the operating temperature of solid oxide fuel cells (SOFCs) is crucial to make this technology commercially viable. In this context, the electrode efficiency at low temperatures could be greatly enhanced by microstructural design at the nanoscale. This work describes alternative microstructural approaches to improve the electrochemical efficiency of the BaCo_0.4Fe_0.4Zr_0.1Y_0.1O_3-δ (BCFZY) cathode. Different electrodes architectures are prepared in a single step by a cost-effective and scalable spray-pyrolysis deposition method. The microstructure and electrochemical efficiency are compared with those fabricated from ceramic powders and screen-printing technique. A complete structural, morphological and electrochemical characterization of the electrodes is carried out. Reduced values of area specific resistance are achieved for the nanostructured cathodes, i.e., 0.067 Ω·cm² at 600 °C, compared to 0.520 Ω·cm² for the same cathode obtained by screen-printing. An anode supported cell with nanostructured BCFZY cathode generates a peak power density of 1 W·cm⁻² at 600 °C.

Turning Detrimental Effect into Benefits: Enhanced Oxygen Reduction Reaction Activity of Cobalt-Free Perovskites at Intermediate Temperature via CO2-Induced Surface Activation

A minor amount of CO₂ in air usually causes a detrimental effect on oxygen activation over a solid oxide fuel cell (SOFC) cathode because insulating surface carbonate is easily formed, which inhibits charge transfer during the oxygen reduction reaction (ORR). In this study, we report that the detrimental effect due to the CO₂ interaction with perovskite oxide can be turned into a beneficial effect for facilitating ORR through tailoring the material composition of the perovskite. More specifically, for cobalt-free SrSc_0.025Nb_0.075Fe_0.9O_3-δ (SSNF), the exposure to the CO₂ atmosphere results in the formation of a minor amount of surface strontium carbonate mainly in the form of a nanofilm over the perovskite surface, which protects the electrode from further corrosion by CO₂, thus achieving a relatively stable performance even under a 10% CO₂-containing air atmosphere. When CO₂-free air is restored, the SrCO₃ is successfully decomposed at intermediate temperatures. As a result, the surface reaction kinetics is recovered to the initial degree while the charge transfer process is obviously improved. An area-specific resistance of only 0.07 Ω cm² is achieved at 650 °C after the CO₂-induced surface activation, much smaller than the original value of 0.13 Ω cm². In addition, the CO₂-treated electrode shows a fairly stable performance for ORR under a subsequent CO₂-free air atmosphere. To create such a beneficial effect, it is critical to tailor the degree of interaction of the perovskite surface with CO₂, while the benchmark Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) shows a too strong interaction with CO₂ with the formation of bulk-phase-like carbonate, which failed to decomposed even when restored with a CO₂-free atmosphere at intermediate temperatures, and as a result, worsened the ORR activity after the CO₂ treatment.

Hybrid Electrochemical Deposition Route for the Facile Nanofabrication of a Cr-Poisoning-Tolerant La(Ni,Fe)O3-δ Cathode for Solid Oxide Fuel Cells

Cr poisoning of cathode materials is one of the main degradation issues hampering the operation of solid oxide fuel cells (SOFCs). To overcome this shortcoming, LaNi_0.6Fe_0.4O_3-δ (LNF) has been developed as an alternative cathode material owing to its superior chemical stability in Cr environments. In this study, we develop a hybrid electrochemical deposition technique to fabricate a nanostructured LNF-gadolinium-doped ceria (GDC) (n-LNF-GDC) cathode with enhanced active reaction sites for the oxygen reduction reaction. For this purpose, Fe and Ni cations are co-deposited onto an electrically conductive carbon nanotube-modified GDC backbone by electroplating, whereas La cations are successively deposited through a chemically assisted electrodeposition method. The proposed method involves a low-temperature (900 °C) calcination step of electrodeposited cations, which avoids the need of fabricating a GDC diffusion barrier layer which is otherwise needed to avoid the formation of insulating phases (e.g., La₂Zr₂O₇) when fabricating by conventional high-temperature (≥1000 °C) sintering. Scanning electron microscopy images reveal a unique nanofibrous structure of n-LNF-GDC, which is believed to play an instrumental role in enhancing the electrochemical characteristics by increasing the active triple-phase boundaries. An anode-supported SOFC with the n-LNF-GDC cathode showed the superior performance of 0.984 W cm^-2 at an intermediate temperature of 750 °C as compared to the power densities of 0.495 and 0.874 W cm^-2 produced by LNF-GDC and state-of-the-art La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF)-GDC composite cathodes fabricated by conventional sintering. A short-term accelerated Cr-poisoning durability test indicated good electrochemical stability of n-LNF-GDC, whereas LSCF exhibited severe degradation. The electrochemically engineered nanostructured n-LNF-GDC can serve as an effective cathode for SOFCs to achieve high performance and long-term durability.

Gas-Permeable Inorganic Shell Improves the Coking Stability and Electrochemical Reactivity of Pt toward Methane Oxidation

Solid oxide fuel cells produce electricity directly by oxidizing methane, which is the most attractive natural gas fuel, and metal nanocatalysts are a promising means of overcoming the poor catalytic activity of conventional ceramic electrodes. However, the lack of thermal and chemical stability of nanocatalysts is a major bottleneck in the effort to ensure the lifetime of metal-decorated electrodes for methane oxidation. Here, for the first time, this issue is addressed by encapsulating metal nanoparticles with gas-permeable inorganic shells. Pt particles approximately 10 nm in size are dispersed on the surface of a porous La_0.75Sr_0.25Cr_0.5Mn_0.5O₃ (LSCM) electrode via wet infiltration and are then coated with an ultrathin Al₂O₃ layer via atomic layer deposition. The Al₂O₃ overcoat, despite being an insulator, significantly enhances the immunity to carbon coking and provides high activity for the electrochemical oxidation of methane, thereby reducing the reaction impedance of the Pt-decorated electrode by more than 2 orders of magnitude and making the electrode activity of the Pt-decorated sample at 650 °C comparable with those reported at 800 °C for pristine LSCM electrodes. These observations provide a new perspective on strategies to lower the operation temperature, which has long been a challenge related to hydrocarbon-fueled solid oxide fuel cells.

Unraveling the Mechanism of Water-Mediated Sulfur Tolerance via Operando Surface-Enhanced Raman Spectroscopy

While several proton-conducting anode materials have shown excellent tolerance to sulfur poisoning, the mechanism is still unclear due largely to the inability to probe miniscule amounts of sulfur-containing species using conventional surface characterization techniques. Here we present our findings in unraveling the mechanism of water-mediated sulfur tolerance of a proton conductor under operating conditions empowered by surface-sensitive, operando surface-enhanced Raman spectroscopy (SERS) coupled with impedance spectroscopy. Contrary to the conventional view that surface-adsorbed sulfur is removed mainly by oxygen anions, it is found that -SO₄ groups on the surface of the proton conductor are converted to SO₂ by a water-mediated process, as confirmed by operando SERS analysis and density functional theory (DFT)-based calculations. The combination of operando SERS performed on a model electrode and theoretical computation offers an effective approach to investigate into complex mechanisms of electrode processes in various electrochemical systems, providing information vital to achieve the rational design of better electrode materials.

Enhanced Anode Performance and Coking Resistance by In Situ Exsolved Multiple-Twinned Co-Fe Nanoparticles for Solid Oxide Fuel Cells

The broad and large-scale application of solid oxide fuel cells (SOFCs) technology hinges significantly on the development of highly active and robust electrode materials. Here, Ni-free anode materials decorated with metal nanoparticles are synthesized by in situ reduction of Fe-doping Sr₂CoMo_1-xFe_xO_6-δ (x = 0, 0.05, 0.1) double perovskite oxides under a reducing condition at 850 °C. The exsolved nanoparticles from the Sr₂CoMo_0.95Fe_0.05O_6-δ (SCMF0.05) lattice are Co-Fe alloys with rich multiple-twinned defects, significantly enhancing the catalytic activity of the SCMF0.05 anode toward the oxidation of H₂ and CH₄. The electrolyte-supported single cell with the reuduced SCMF0.05 anode reaches peak power densities as high as 992.9 and 652.3 mW cm^-2 in H₂ and CH₄ at 850 °C, respectively, while maintaining superior stability (∼50 h at 700 °C). The reduced SCMF0.05 anode also demonstrates excellent coking resistance in CH₄, which can be attributed to the increased oxygen vacancies due to Fe doping and the effective catalysis of multiple-twinned Co-Fe alloy nanoparticles for reforming of CH₄ to H₂ and CO. The findings in this work may provide a new insight for the design of highly active and durable anode catalysts in SOFCs.

Formation of Nanocomposite Solid Oxide Fuel Cell Cathodes by Preferential Clustering of Cations from a Single Polymeric Precursor

Conventional composite cathodes used in solid oxide fuel cells (SOFCs) are fabricated by co-sintering of electrocatalyst and ionic conductor powders at 1100-1250 °C. The relatively high-temperature heat treatments required to ensure bonding among the powders and between the powders and electrolyte results in the formation of resistive phases and coarse microstructures corresponding to short triple-phase boundary (TPB) length and, consequently, low oxygen reduction activity. In the present work, to achieve long TPBs and avoid resistive phase formation, we propose to fabricate nanocomposite La_0.8Sr_0.2MnO₃-Ce_0.8Sm_0.2O₂ (LSM-SDC) and La_0.8Ca_0.2MnO₃-Ce_0.8Sm_0.2O₂ (LCM-SDC) thin film cathodes by a low-temperature method, which involves the use of a single polymeric precursor solution containing all the respective cations. Owing to the molecular level mixing and the liquid lack of any powder-based starting material, we envision that preferential clustering of cations forming nanoscale electrocatalyst and ionic conductor particles will take place upon heat treatment at relatively low temperatures of 600-800 °C. Here, we report for the first time in the literature, a correlation between the heat-treatment temperature-phase evolution-cluster formation-surface chemistry evolution and electrochemical activity of nanocomposite thin film cathodes fabricated from a single polymeric precursor. Our experiments reveal that highest electrochemical activity is achieved when the electrocatalyst phase is poorly crystallized, complete clustering of cations takes place, and A-site dopant segregation at the surface is minimal.

Ultrathin Atomic Layer-Deposited CeO2 Overlayer for High-Performance Fuel Cell Electrodes

Obtaining a catalyst with high activity and thermal stability is essential for high-performance energy conversion devices operating at an elevated temperature. Herein, the design and fabrication of a heterogeneous catalyst with an ultrathin CeO₂ overlayer via atomic layer deposition (ALD) on Pt electrodes for low-temperature solid oxide fuel cells (LT-SOFCs) is reported. The cell with a CeO₂-overcoated (five ALD cycles) Pt cathode shows lower activation resistance by 50% after a 10 h operation and higher thermal stability by a factor of 2 compared with the cell with a Pt-only cathode, which is known to be the best single catalyst at 450 °C. Eventually, a thin-film SOFC with a highly active and stable CeO₂-overcoated cathode based on an anodized aluminum oxide (AAO) substrate demonstrates a high peak power density of 800 mW cm^-2 at 500 °C, which is the highest performance ever reported for an AAO-based SOFC at this temperature.

Vanadium-Doped Strontium Molybdate with Exsolved Ni Nanoparticles as Anode Material for Solid Oxide Fuel Cells

Vanadium-doped strontium molybdate (SVM) has been investigated as a potential anode material for solid oxide fuel cells due to its high electronic conductivity of about 1000 S cm^-1 at 800 °C in reducing atmospheres. In this work, NiO is introduced to SVM with the B-site excess design to induce in situ growth of Ni nanoparticles in the anodic operational conditions. The Ni particles are exsolved from the parent oxide phase as clearly demonstrated with various techniques including X-ray diffraction, X-ray photoelectron spectroscopy, scanning electron microscopy, and transmission electron microscopy. The exsolved Ni nanoparticles significantly boost the electrocatalytic activity toward fuel oxidation reaction, improving the peak power density by 160% from 0.21 to 0.56 W cm^-2 at 800 °C when using H₂ as the fuel, meanwhile reducing the total interfacial polarization resistance by 56% from 0.81 to 0.36 Ω cm². The Ni-exsolved SVM anode also shows excellent catalytic activity toward H₂S-containing and hydrocarbon fuels, providing peak power densities of 0.43, 0.36, and 0.22 W cm^-2 at 800 °C for H₂-50 ppm H₂S, syngas, and ethanol, respectively. In addition, the cell with the Ni-exsolved SVM anode presents a stable power output, indicating that the Ni-SVM is a potential SOFC anode electrocatalyst for various fuels.

Approaching Durable Single-Layer Fuel Cells: Promotion of Electroactivity and Charge Separation via Nanoalloy Redox Exsolution

Single-layer fuel cells (SLFCs) based on mixed semiconductors and ionic conductors demonstrate  simplified material preparation and fabrication procedure and possess high performance potentially. However, the operational stability and principle of SLFCs have not yet been convinced of either commercialization or fundamental interests. We hereby report on the employment of a perovskite oxide-based phase-structured redox-stable semiconductor prior to determining a possible solution that improves the durability of the SLFC. Feasible working principles are established and an in-depth understanding of the short-circuit-free phenomenon in SLFCs with the mixed ionic and electronic conductors is provided. Additionally, a smart material design and cell structure processing are also proposed. An extended nonstop testing period of up to 2 days confirms the project feasibility and improved durability of the SLFCs, achieved by replacing the unstable lithiated oxide phase with redox-stable perovskite oxide, though the electrochemical performance is sacrificed. The precipitated metal/alloy nanoparticle on perovskite oxide not only improves the electrode reaction kinetics but also facilitates the charge separation and ionic conduction in SLFCs, consequently enhancing the fuel cell performance and electrical efficiency. The results confirmed the potential of stable operation for future practical deployment of SLFCs via appropriate selection of material and cell structure design. It is greatly believed that the physical junction plays a crucial role in overcoming the internal short-circuit issue of SLFCs.

La0.6Sr0.4Co0.2Fe0.8O3-δ/CeO2 Heterostructured Composite Nanofibers as a Highly Active and Robust Cathode Catalyst for Solid Oxide Fuel Cells

The lack of highly active and robust catalysts for the oxygen reduction reaction (ORR) at the intermediate temperatures significantly hinders the commercialization of solid oxide fuel cells (SOFCs). Here, we report a novel heterostructured composite nanofiber cathode composed of La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) and CeO₂ nanoparticles, synthesized by using a coaxial electrospinning technique, which exhibits remarkably enhanced ORR activity and durability as compared to single LSCF powder and nanofibers. This cathode achieves a polarization resistance of 0.031 Ω cm² at 700 °C, approximately 1/5 of that for the LSCF powder cathode (0.158 Ω cm²). Such enhancement can be attributed to the continuous paths provided by nanofibers for efficient mass/charge transport and the interdiffusion of La and Ce at the heterointerface which leads to more oxygen vacancy formation. Furthermore, the anode-supported cell with the LSCF/CeO₂ composite cathode shows excellent stability (0.4 V for ∼200 h at 600 °C) because of suppression of Sr segregation in LSCF by introducing CeO₂ and the structure of heterogeneous nanofibers. These results indicate that the microstructure design of this heterostructured composite nanofiber for LSCF/CeO₂ is extremely effective for enhancing ORR activity and stability. This finding may provide a new strategy for the microstructure design of highly active and robust ORR catalysts in SOFCs.

Advanced Fuel Cell Based on New Nanocrystalline Structure Gd0.1Ce0.9O2 Electrolyte

Lowering the operating temperature is a universal R&D challenge for the development of low-temperature (<600 °C) solid oxide fuel cells (SOFCs) that meet the demands of commercialization. Regarding the traditional electrolyte materials of SOFCs, bulk diffusion is the main ionic conduction mechanism, which is primarily affected by the bulk density and operating temperatures. In this study, we report a new mechanism for the Ce_0.9Gd_0.1O_2-δ (GDC) electrolyte based on a nanocrystalline structure with surface or grain boundary conduction, exhibiting an extremely high ionic conductivity of 0.37 S·cm^-1 at 550 °C. The fuel cell with the nanocrystalline structure GDC electrolyte (0.5 mm in thickness) can deliver a remarkable peak power density of 591.8 mW·cm^-2 at 550 °C, which is approximately 3.5 times higher than that for the cell with the GDC electrolyte densified at 1550 °C. An amorphous layer enriched by oxygen vacancies was found at the surface of the nano-GDC particles in the fuel cell test atmosphere, which was attributed to the ion conduction channel of the grain boundary diffusion. The ionic conduction at the interfaces between the particles was discovered to be the dominant conduction mechanism of the nanocrystalline structure GDC electrolyte. Oxygen ions and protons were determined to be the charge carriers in this interfacial conduction phenomenon, and the conduction of oxygen ions was dominant.

A-Site Ordered Double Perovskite with in Situ Exsolved Core-Shell Nanoparticles as Anode for Solid Oxide Fuel Cells

A highly active anode material for solid oxide fuel cells resistant to carbon deposition is developed. Co-Fe co-doped La_0.5Ba_0.5MnO_3-δ with a cubic-hexagonal heterogeneous stucture is synthesized through the Pechini method. An A-site ordered double perovskite with Co_0.94Fe_0.06 alloy-oxide core-shell nanoparticles on its surface is formed after reduction. The phase transition and the exsolution of the nanoparticles are investigated with X-ray diffraction, thermogravimetric analysis, and high-resolution transmission electron microscope. The exsolved nanoparticles with the layered double-perovskite supporter show a high catalytic activity. A single cell with that anode and a 300 μm thick La_0.8Sr_0.2Ga_0.8Mg_0.2O_3-δ electrolyte layer exhibits maximum power densities of 1479 and 503 mW cm^-2 at 850 °C with wet hydrogen and wet methane fuels, respectively. Moreover, the single cell fed with wet methane exhibits a stable power output at 850 °C for 200 h, demonstrating a high resistance to carbon deposition of the anode due to the strong anchor of the exsolved nanoparticles on the perovskite parent. The oxide shell also preserves the metal particles from coking.

Understanding Structure-Activity Relationships in Sr1- xY xCoO3-δ through in Situ Neutron Diffraction and Electrochemical Measurements

In this work, we report a systematic study on temperature-dependent local structural evolution, oxygen stoichiometry, and electrochemical properties of an oxygen-deficient perovskite Sr_0.7Y_0.3CoO_3-δ (SYC30) for oxygen electrocatalysis. The obtained results are then closely compared with its analogue Sr_0.9Y_0.1CoO_3-δ (SYC10) of different crystal structures to establish structure-activity relationships. The comparison shows that both SYC30 and SYC10 consist of alternate layers of oxygen-deficient Co1-polyhedra and oxygen-saturated Co2-octahedra with Co1-polyhedra being responsible for V_o^•• migration. It is also found that the distribution and concentration of oxygen vacancies within the Co1-layer are, respectively, less symmetrical and lower in SYC30 than those in SYC10, making the former unfavorable for oxygen transport. A molecular orbital energy analysis reveals that the energy gap between Fermi level and O 2p level in the active Co1-polyhedra is larger in SYC30 than that in SYC10, further suggesting that SYC10 is a better oxide-ion conductor and thus a better electrocatalyst for oxygen reduction reaction, which is unambiguously confirmed by the subsequent electrochemical measurements.