Processing of graded anode-supported micro-tubular SOFCs based on samaria-doped ceria via gel-casting and spray-coating

A simple gel-casting method was successfully combined with the spray-coating technique to manufacture graded anode-supported micro-tubular solid oxide fuel cells (MT-SOFCs) based on samaria-doped ceria (SDC) as an electrolyte. Micro-tubular anodes were shaped by a gel-casting method based on a new and simple forming technique that operates as a syringe. The aqueous slurry formulation of the NiO–SDC substrate using agarose as a gelling agent, and the effect of spray-coating parameters used to deposit the anode functional layers (AFLs) and electrolyte were investigated. Furthermore, pre-sintering temperature of anode substrates was systematically studied to avoid the anode–electrolyte delamination and obtain a dense electrolyte without cracks, after co-sintering process at 1450 °C. Despite the high shrinkage of substrate (∼70%), an anode porosity of ∼37% was achieved. MT-SOFCs with ∼2.5 mm of outer diameter, 370 μm thick substrate, 20 μm thick AFLs and 15 μm thick electrolyte were successfully obtained. The use of AFLs with 30:70 and 50:50 wt% NiO–SDC allowed to obtain a continuous gradation of composition and porosity in the anode–electrolyte interface.