Recent advances in microstructural control via thermal spraying for solid oxide fuel cells

This article provides a comprehensive review of the microstructure development of plasma-sprayed ceramic coatings in relation to the deposition of functional layers within solid oxide fuel cells (SOFCs). The focus is primarily on thermal-sprayed porous coatings for both the anode and cathode, as well as plasma-sprayed dense ceramic coatings for the electrolyte, considering both post-treatment methods and processes without post-treatment. The review also encompasses the control of composition and crystalline structure in plasma-sprayed perovskite cathode materials. Furthermore, the article discusses the advantages, limitations, and prospects of utilizing thermal spray processes for the deposition of SOFC electrolytes. The design of highly efficient electrodes with enhanced triple-phase boundaries is introduced as a pivotal aspect. Additionally, the integrated fabrication of SOFCs through thermal spray techniques is presented to highlight the potential of these processes in manufacturing SOFCs with various configuration designs.