Development of a Ni/Al ₂O ₃ cermet-supported tubular solid oxide fuel cell assembled with different functional layers by atmospheric plasma-spraying

A cermet-supported tubular configuration amenable to preparation by a relatively low-cost thermal spraying process is proposed. An Al ₂O ₃-Ni cermet thick deposit prepared by flame spraying is employed as both support tube and anode current collector. Atmospheric plasma spraying (APS) has been employed to prepare the anode, cathode, and stabilized ZrO ₂-based electrolyte with the aim of reducing manufacturing costs. Gas-tightness of the APS electrolyte has been achieved by a postdensification process. The effects of the densification process on the gas-tightness of the plasma-sprayed YSZ electrolyte and the open-circuit voltage of the SOFC have been investigated. The effects of the microstructures of the plasma-sprayed anode, electrolyte, and cathode on the performance of the SOFC test cell have been investigated.