Enhancing the electrochemical performance of Ni-based electrodes via flash light sintering for metal-supported solid oxide fuel cells (MS-SOFCs)

Abstract

Metal-supported solid oxide fuel cells (MS-SOFCs) have recently gained significant attention as an advanced SOFC technology, owing to their excellent mechanical robustness, ease of handling, and high manufacturability. The use of metal substrates enables improved durability under thermal and redox cycling, and allows for thinner electrolyte layers, contributing to enhanced performance. However, their fabrication typically requires high-temperature sintering to ensure adequate material properties and adhesion, as most SOFC components are ceramic. These high-temperature processes can lead to undesirable effects, including metal support oxidation, chemical side reactions, and accelerated particle growth, which degrade cell performance. This study introduces an ultra-fast sintering approach for MS-SOFC fabrication by directly integrating stainless-steel metal supports with nickel-yttria-stabilized zirconia (Ni-YSZ) composite anode active layers. The application of flash light sintering—an innovative ultra-fast technique—effectively suppressed Ni catalyst particle growth, expanding the electrochemical reaction area while minimizing material diffusion between the metal support and anode layer. As a result, the fabricated cells achieved a stable open-circuit voltage (OCV) exceeding 1 V at 650 °C and a peak power density of 412 mW/cm2, representing an approximately 426.3% performance improvement over conventionally sintered cells. This research presents a transformative strategy for SOFC manufacturing, addressing the challenges of conventional long-duration heat treatments and demonstrating significant potential for advancing energy conversion technologies.