Three-dimensional nanostructured bilayer solid oxide fuel cell with 1.3 W/cm(2) at 450 °C.

Obtaining high power density at low operating temperatures has been an ongoing challenge in solid oxide fuel cells (SOFC), which are efficient engines to generate electrical energy from fuels. Here we report successful demonstration of a thin-film three-dimensional (3-D) SOFC architecture achieving a peak power density of 1.3 W/cm(2) obtained at 450 °C. This is made possible by nanostructuring of the ultrathin (60 nm) electrolyte interposed with a nanogranular catalytic interlayer at the cathode/electrolyte interface. We attribute the superior cell performance to significant reduction in both the ohmic and the polarization losses due to the combined effects of employing an ultrathin film electrolyte, enhancement of effective area by 3-D architecture, and superior catalytic activity by the ceria-based interlayer at the cathode. These insights will help design high-efficiency SOFCs that operate at low temperatures with power densities that are of practical significance.

Simultaneous Performance and Stability Enhancement in Intermediate Temperature Solid Oxide Fuel Cells by Powder-Atomic Layer Deposited LSCF@ZrO2 Cathodes.

Employing porous structures is essential in high-performance electrochemical energy devices. However, obtaining uniform functional coatings on high-tortuosity structures can be challenging, even with specialized processes such as atomic layer deposition (ALD). Herein, a novel method for achieving a porous composite electrode for solid oxide fuel cells by coating La0.6 Sr0.4 Co0.2 Fe0.8 O3 -δ (LSCF) powders with ZrO2 using a powder ALD process is presented. Unlike conventional ALD, powder ALD can be used to fabricate extremely uniform coatings on porous electrodes with a thickness of tens of micrometers. The powder ALD ZrO2 coating is found to effectively suppress chemical degradation of the LSCF electrodes. The cell with the powder ALD coated cathode shows a 2.2 times higher maximum power density and 60% lower thermal degradation in activation resistance than the bare LSCF cathode cell at 700-750 °C. The result demonstrated in this study is expected to have significant implications for high-performance and durable electrodes in energy conversion/storage devices.

Nanotubular array solid oxide fuel cell.

This report presents a demonstration and characterization of a nanotubular array of solid oxide fuel cells (SOFCs) made of one-end-closed hollow tube Ni/yttria-stabilized zirconia/Pt membrane electrode assemblies (MEAs). The tubular MEAs are nominally ∼5 µm long and have <500 nm outside diameter with total MEA thickness of nearly 50 nm. Open circuit voltages up to 660 mV (vs air) and power densities up to 1.3 µW cm(-2) were measured at 550 °C using H2 as fuel. The paper also introduces a fabrication methodology primarily based on a template process involving atomic layer deposition and electrodeposition for building the nanotubular MEA architecture as an important step toward achieving high surface area ultrathin SOFCs operating in the intermediate to low-temperature regime. A fabricated nanotubular SOFC theoretically attains a 20-fold increase in the effective surface, while projections indicate the possibility of achieving up to 40-fold.

Enhanced oxygen exchange on surface-engineered yttria-stabilized zirconia.

Ion conducting oxides are commonly used as electrolytes in electrochemical devices including solid oxide fuel cells and oxygen sensors. A typical issue with these oxide electrolytes is sluggish oxygen surface kinetics at the gas-electrolyte interface. An approach to overcome this sluggish kinetics is by engineering the oxide surface with a lower oxygen incorporation barrier. In this study, we engineered the surface doping concentration of a common oxide electrolyte, yttria-stabilized zirconia (YSZ), with the help of atomic layer deposition (ALD). On optimizing the dopant concentration at the surface of single-crystal YSZ, a 5-fold increase in the oxygen surface exchange coefficient of the electrolyte was observed using isotopic oxygen exchange experiments coupled with secondary ion mass spectrometer measurements. The results demonstrate that electrolyte surface engineering with ALD can have a meaningful impact on the performance of electrochemical devices.

Aberration-Corrected TEM Imaging of Oxygen Occupancy in YSZ.

We present atomic-scale imaging of oxygen columns and show quantitative analysis on the occupancy of the columns in yttria-stabilized zirconia (YSZ) using aberration-corrected TEM operated under the negative Cs condition. Also, individual contributions both from oxygen column occupancy and the static displacement of oxygen atoms due to occupancy change to the observed column intensities of TEM images were systematically investigated using HRTEM simulation. We found that oxygen column intensity is governed primarily by column occupancy rather than by static displacement of oxygen atoms. Utilizing the aberration-corrected TEM capability and HRTEM simulation results, we experimentally verified that oxygen vacancies segregate near the single grain boundary of a YSZ bicrystal. The methodology and the high spatial resolution characterization tool employed in the present study provide insights into the distribution of oxygen vacancies in the bulk as well as near grain boundaries and pave the way for further investigation and atomic-scale analysis in other important oxide materials.

Atomic scale verification of oxide-ion vacancy distribution near a single grain boundary in YSZ.

This study presents atomic scale characterization of grain boundary defect structure in a functional oxide with implications for a wide range of electrochemical and electronic behavior. Indeed, grain boundary engineering can alter transport and kinetic properties by several orders of magnitude. Here we report experimental observation and determination of oxide-ion vacancy concentration near the Σ13 (510)/[001] symmetric tilt grain-boundary of YSZ bicrystal using aberration-corrected TEM operated under negative spherical aberration coefficient imaging condition. We show significant oxygen deficiency due to segregation of oxide-ion vacancies near the grain-boundary core with half-width < 0.6 nm. Electron energy loss spectroscopy measurements with scanning TEM indicated increased oxide-ion vacancy concentration at the grain boundary core. Oxide-ion density distribution near a grain boundary simulated by molecular dynamics corroborated well with experimental results. Such column-by-column quantification of defect concentration in functional materials can provide new insights that may lead to engineered grain boundaries designed for specific functionalities.

Enhancing charge transfer kinetics by nanoscale catalytic cermet interlayer.

Enhancing the density of catalytic sites is crucial for improving the performance of energy conversion devices. This work demonstrates the kinetic role of 2 nm thin YSZ/Pt cermet layers on enhancing the oxygen reduction kinetics for low temperature solid oxide fuel cells. Cermet layers were deposited between the porous Pt cathode and the dense YSZ electrolyte wafer using atomic layer deposition (ALD). Not only the catalytic role of the cermet layer itself but the mixing effect in the cermet was explored. For cells with unmixed and fully mixed cermet interlayers, the maximum power density was enhanced by a factor of 1.5 and 1.8 at 400 °C, and by 2.3 and 2.7 at 450 °C, respectively, when compared to control cells with no cermet interlayer. The observed enhancement in cell performance is believed to be due to the increased triple phase boundary (TPB) density in the cermet interlayer. We also believe that the sustained kinetics for the fully mixed cermet layer sample stems from better thermal stability of Pt islands separated by the ALD YSZ matrix, which helped to maintain the high-density TPBs even at elevated temperature.