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Solid oxide fuel cells (SOFCs) have attracted great interest as an alternative potential way to become the most efficient and cleanest electrochemical energy conversion system. The commercialization of SOFC technology is hindered by the degradation of component materials. The durable and high performing cathode materials is of immense importance in the durability improvement of SOFCs. Cobaltite type perovskite-based oxides have shown remarkable results but cation migration and formation of the insulating phases within and near the interface between cathode and electrolyte is often observed, which impacts greatly on the electrochemical performance and durability. Therefore, the reaction barrier layer (interlayer) typically made of doped ceria is required between cathode and electrolyte. The stability of this layer due to cations cross-migration between cathode and electrolyte and interdiffusion with electrolyte during fabrication and operation is presently one of the foremost issues (motivation) in the SOFC industry. The chemical and structural disparity associated with the cations migration and interdiffusion could affect the stability and functionality of different layers of SOFC. Understanding the formation of secondary phases and their evolution during the operating lifespan is thought-provoking because of the complexity of the system and the occurrence of numerous other processes simultaneously. In this review paper, the recent progress and advancement in this extent are presented, emphasizing the key driving forces, kinetics, analysis techniques at the micro- and nano-scale levels, and cations migration in extensively studied perovskite-based materials. An insightful understanding of the interdiffusion phenomenon taking place in the cathode/electrolyte/interlayer of SOFCs and control measures are then highlighted which is important to achieve the rational design of highly efficient SOFC with outstanding stable performance.

Solid oxide fuel cells (SOFCs) capable of operating at low to intermediate temperatures (600–750 °C) are vital for the development of robust SOFC power generation systems. In this regard, the oxygen reduction reaction is the rate-limiting step that requires new highly active catalysts or drastic improvements in the cathode microstructure when using the conventional cathode materials. Here, we report a parametric study on electrodeposition for synthesizing nanostructured cathodes for the SOFCs by producing a nanofibrous LaCoO3 cathode. The synthesis of the nanofibrous LaCoO3 involves preparing an electrically conductive template of carbon nanotubes onto the walls of a porous scaffold made of oxide-ion-conducting material followed by co-electrodeposition of La and Co hydroxides from an aqueous mixed-metal nitrate solution. Then, the deposited metal hydroxides are thermally converted to the LaCoO3 perovskite phase through low-temperature calcination performed at 800 °C. LaCoO3 microstructure is optimized as a function of deposition time, applied current, and solution concentration to obtain a nanofibrous morphology. Anode-supported SOFCs with the nanofibrous LaCoO3 cathode are tested for their electrochemical performance and durability. A durable performance obtained during the 200 h stability tests, performed at 750 and 800 °C and under a galvanostatic load of 1 A cm−2, shows the potential of the electrodeposition for producing robust nanostructured SOFC cathodes.

For anode supported solid oxide fuel cells (SOFCs), the strength and durability of the porous cermet support during long-term operation is critical for the reliability of the cells and stacks. The effect of adding nano-Al 2 O 3 on the long-term durability of the mechanical strength of nickel-yttria stabilized zirconia (Ni-YSZ) based SOFC anode supports was investigated in this study. The SOFC anode support materials, Ni-3YSZ (3 mol% YSZ), Ni-8YSZ (8 mol% YSZ), and nano-Al 2 O 3 added Ni-YSZ composites, were subjected to a long-term degradation test at 900 °C and 30% humidity in an H 2 environment and after 1000 h exposure, the flexural strength, phase, and microstructural changes were analyzed. The results suggest that the addition of nano-Al 2 O 3 to Ni-3YSZ improves the long-term strength and durability of the cermet while its addition to Ni-8YSZ cermet did not show any significant changes in the strength degradation behavior of the Ni-8YSZ based anode support. Further analysis by SEM and XRD shows that the tetragonal to monoclinic phase transformation in partially stabilized zirconia was suppressed due to the addition of nano-Al 2 O 3 in Ni-3YSZ resulting in improved long-term stability and higher mechanical strength. Replacing the Ni-8YSZ anode support with nano-Al 2 O 3 added Ni-3YSZ might significantly reduce the material cost of SOFCs without compromising long-term strength durability, thus bringing SOFCs a step closer to commercialization.

A solid oxide fuel cell (SOFC) stack requires metallic interconnects to electrically connect unit cells, while preventing fuel from mixing with oxidant. During SOFC operations, chromia scales continue to grow on the interconnect surfaces, resulting in a considerable increase of interfacial resistance, and at the same time, gaseous Cr species released from the chromia scales degrades the cathode performance. To address these problems, in this study, protective Mn2CuO4 coatings are fabricated on metallic interconnects (Crofer 22 APU) via a plasma spray (PS) process. The PS technique involves direct spray deposition of molten Mn2CuO4 onto the interconnect substrate and leads to the formation of high-density Mn2CuO4 coatings without the need for post-heat-treatment. The thickness, morphology, and porosity of the PS-Mn2CuO4 coating are found to depend on the processing parameters, including plasma arc power, gas flow rate, and substrate temperature. The PS-Mn2CuO4 coating fabricated with optimized parameters is completely impermeable to gases and has high adhesion strength on the interconnect substrate. Furthermore, no resistive chromia scales are formed at the coating/substrate interface during the PS process. As a result, the PS-Mn2CuO4-coated interconnects show a very low area-specific resistance below 10 mΩ cm2 at 800 °C in air and excellent stability during both continuous operation and repeated thermal cycling. This work suggests that an appropriate combination of the material and coating process provides a highly effective protective layer for SOFC interconnects.

The purpose of this study was to fabricate a porous supporting cathode for direct carbon solid oxide fuel cells (DCFC). Therefore, the effect of Gd0.1Ce0.9O2−δ (GDC) addition on the phase stability, sintering behavior, thermal expansion, and porosity of La0.65Sr0.3MnO3−δ/(Y2O3)0.08(ZrO2)0.92 (LSM/YSZ) composite was evaluated. The sintering temperature and the porosity of the LSM/YSZ composite were observed to increase with increase in the amount of GDC. An LSM/YSZ/GDC tri-composite with optimized properties was selected to fabricate the tubular cathode-supported DCFCs (LSM/YSZ/GDC|YSZ|NiO/YSZ) through extrusion, slurry coating, and co-firing. A special chamber was designed for the DCFC operation of the tubular cell. Electrochemical characterization was performed by measuring the polarization curves and electrochemical impedance spectroscopy, using the syngas produced by in situ steam gasification of carbon black.

Equal amounts of Gd 0.1 Ce 0.9 O 2− δ (GDC) were added to La 0.65 Sr 0.3 MnO 3− δ /(Y 2 O 3 ) 0.08 (ZrO 2 ) 0.92 (LSM/YSZ) powder either by physical mixing or by sol–gel process, to produce a porous cathode support for solid oxide fuel cells (SOFCs). The effect of the GDC mixing method was analyzed in view of sinterability, thermal expansion coefficient, microstructure, porosity, and electrical conductivity of the LSM/YSZ composite. GDC infiltrated LSM/YSZ (G-LY) composite showed a highly porous microstructure when compared with mechanically mixed LSM/YSZ (LY) and LSM/YSZ/GDC (LYG) composites. The cathode support composites were used to fabricate the button SOFCs by slurry coating of YSZ electrolyte and a nickel/YSZ anode functional layer, followed by co-firing at 1250 °C. The G-LY composite cathode-supported SOFC showed maximum power densities of 215, 316, and 396 mW cm −2 at 750, 800, and 850 °C, respectively, using dry hydrogen as fuel. Results showed that the GDC deposition by sol–gel process on LSM/YSZ powder before sintering is a promising technique for producing porous cathode support for the SOFCs.

Long-term performance degradation of solid oxide fuel cell (SOFC) cathode as a function of gadolinium doped ceria (GDC) interlayer thickness has been studied under accelerated operating conditions. For this purpose, SOFC half-cells with GDC interlayer thicknesses of 2.4, 3.4 and 6.0 µm were fabricated and tested for 1000 h at 900 °C under constant current density of 1 A/cm 2 . The half-cells consisted of lanthanum strontium cobalt ferrite (LSCF)/GDC composite cathode, GDC interlayer, scandia-ceria stabilized zirconia electrolyte and platinum anode as a counter electrode. Area specific resistance (ASR) of the half-cells was continuously measured over time. Higher increase in ASR was observed for the half-cells with GDC interlayer thickness of 2.4 and 6.0 µm, which is attributed to higher strontium (Sr) diffusion towards electrolyte and to cathode/GDC interface delamination coupled with small Sr diffusion, respectively. However, half-cell with GDC interlayer thickness of 3.4 µm showed smaller degradation rate due to highly dense GDC interlayer which had less interfacial resistance and suppressed Sr diffusion towards electrolyte.

This paper summarizes various mechanisms involved in the degradation of Solid Oxide Fuel Cells (SOFCs) anode. Ni–YSZ is the most commonly used anode material in SOFCs, since it has various advantages such as high catalytic activity for H2, methane reforming, stability and high electronic conductivity. However, this material shows various types of degradations when used at high temperatures for prolonged time periods. The different types include Ni grain growth by sintering, carbon coking, sulfur poisoning and redox cycling. The in-detail mechanism of each type of degradation followed by different controlling mechanisms has been presented in greater detail. Modifications in the Ni–YSZ microstructure and optimization of operating conditions can effectively increase the life time of SOFCs and help in their commercialization.