This project aims to advance the science and engineering of porous electrodes in solid oxide fuel cells (SOFCs), specifically metal-supported SOFCs. Metal-supported SOFCs have the potential to become a pivotal technology for space missions due to their fast startup, strength, and cost-effectiveness. However, challenges remain in achieving high power density and long lifetimes. To address these obstacles, we propose integrating additive manufacturing (AM) and plasma electrolytic oxidation (PEO) coating to develop new electrodes and novel electrochemical reactor designs. PEO refers to transforming the conductive substrate into a ceramic oxide layer through a high-voltage electrochemical process. This pioneering integration of AM and PEO coating has the potential to enhance the performance and durability of SOFCs.
The main objectives are as follows:
Objective 1: First, to achieve precise microstructural control and create porous structures, we will use laser powder bed fusion as a well-known AM. The goal is to gain predictable control of the porous morphologies for a thoroughly new functionally graded design (graded-porosity and bi-/tri-modal pore size distributions) as an anode for SOFCs and to establish manufacturing-microstructure-performance relationships.
Objective 2: Then, we will create a thin dense layer (< 1 µm) as an electrolyte and a functional porous electrode as a cathode using PEO coating. We will establish composition-performance-durability relationships and leverage this knowledge to functionalize porous microstructures.
Objective 3: Building upon the two previous developments, we will develop a new cell concept for SOFCs and will evaluate the electrochemical performance and stability of the so-developed cell. The implementation of this novel concept will provide efficient pathways for developing graded porous layers with highly controlled surface chemicals and texture for next-generation fuel cells for future space missions.
