Influence of Anode Functional Layers on Electrochemical Performance and Mechanical Strength in Microtubular Solid Oxide Fuel Cells Fabricated by Gel-Casting

Anode-supported microtubular solid oxide fuel cells (mT-SOFCs) using samaria-doped ceria (SDC) as electrolyte were fabricated, varying the composition and number of anode functional layers (AFLs), by combining the aqueous gel-casting and spray-coating techniques. Suitable aqueous slurry formulation of NiO–SDC was prepared using agarose as a gelling agent for gel-casting of tubular supports. Afterward, 40:60 and 50:50 NiO:SDC (wt %) as AFLs and SDC electrolyte were deposited by spray-coating and subsequently co-sintered. Finally, mT-SOFCs with 2.5 mm outer diameter and thicknesses of 380 μm support; 0, 12, and 24 μm AFLs; 15 μm electrolyte; and 30 μm cathode were obtained. The influence of AFLs on the performance and mechanical integrity was investigated for the three cells. For this purpose, electrochemical and mechanical tests at both macroscopic and micro-/nanometric scales (at the AFLs region) were determined by flexural strength and nanoindentation techniques, respectively. The results evidence that the use of AFLs with an adequate composition and microstructure in the mT-SOFCs is required to improve the performance and mechanical strength of the cell. The cell with a single-layer AFL of 50:50 NiO:SDC (wt %) and 12 μm thickness exhibited the best performance (0.52 W·cm–2) at 650 °C using hydrogen as fuel and air as oxidant.