Metal-Supported Solid Oxide Fuel Cells with Exceptionally High Power Density for Range Extender Systems

Solid oxide fuel cells (SOFCs) exhibit potential to become a key technology for future clean energy systems. The metal-supported SOFC exhibits decisive strengths like fast start-up capability, mechanical robustness, and acceptable cost, making it the concept of choice for mobile applications. As a promising example, SOFC-powered range extenders for electric vehicles offer fast refueling and significantly increased driving range, while lowering size, weight, and the cost of the vehicle’s battery. Here, we report the development of a metal-supported SOFC aiming at exceptionally high power density. A knowledge-based improvement of all electrochemically active cell components enables a performance increase up to a factor of 10 and demonstrates the effectiveness of target-oriented optimization of processing and microstructure. Ultimately, enhanced cells meet the industrial performance target by providing a current density of 2.8 A × cm−2 at 650°C and 0.7 V, setting a benchmark for SOFC performance.