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[Display omitted] • The new Pr 0.5 Sr 0.5 Fe 0.9 Mn 0.1 O 3 cathode was prepared. • The Mn-doping method mitigated the high thermal expansion of Pr 0.5 Sr 0.5 FeO 3. • The oxygen vacancy formation and proton diffusion were improved with Mn-doping. • Better fuel cell performance was obtained with the cathode using Mn-doping. The traditional Pr 0.5 Sr 0.5 FeO 3 (PSF) cathode is customized with Mn cations to generate the new Pr 0.5 Sr 0.5 Fe 0.9 Mn 0.1 O 3 (PSFMn) cathode for proton-conducting solid oxide fuel cells (H-SOFCs). Compared to the PSF oxide, the new PSFMn has a reduced thermal expansion, making it more compatible with electrolytes. Furthermore, Mn-doping enhances oxygen vacancy production in PSF, as revealed by experimental and first-principle calculations. More crucially, doping Mn into PSF improves proton diffusion kinetics, resulting in quicker proton diffusion and surface exchange. As a result, the H-SOFC with the PSFMn cathode achieves an output of 1446 mW cm−2 at 700 °C, but the PSF cell only achieves fuel cell performance of 1009 mW cm−2. The fundamental cause of the increased cell performance is the significantly reduced polarization resistance, implying that using the Mn-doping strategy enhances the cathode kinetics of conventional PSF cathodes for H-SOFC. [ABSTRACT FROM AUTHOR]

[Display omitted] • The diffusion of Ni from the anode to the electrolyte is revealded for H-SOFC. • The diffused Ni has significnalty influeced the performance of fuel cells. • Microwave sintering can mitigate the Ni diffusion at the interface. • Better performance is obtained with the microwave sintered fuel cell. Although Ni-based anodes are commonly employed in proton-conducting solid oxide fuel cells (H-SOFCs), interfacial diffusion of Ni from the anode to the electrolyte is difficult to avoid, resulting in lower electrolyte and fuel cell performance. In this study, the electrolyte/anode half-cells are co-sintered using a microwave sintering process, providing a lower co-sintering temperature than the standard sintering approach. The lower co-sintering temperature minimizes Ba-evaporation at the electrolyte and mitigates anode/electrolyte interfacial Ni diffusion, resulting in decreased electrolyte and interfacial polarization resistance. The microwave-sintered cell outperforms the traditionally sintered cell in electrochemical performance, with higher fuel cell performance and lower cell resistances. Furthermore, the improved interfacial condition improves the fuel cell's long-term durability, allowing the cell to operate for 200 h without detectable degradation. This study presents an intriguing and simple way to reduce anode/electrolyte interfacial Ni diffusion, which improves fuel cell output and operational stability. [ABSTRACT FROM AUTHOR]