Abstract: A method of forming an interconnect for an electrochemical device stack includes loading a die with an interconnect material comprising an interconnect body powder comprising chromium and iron, and spark plasma sintering (SPS) the interconnect material to form a body of the interconnect.

Abstract: A fuel cell system includes fuel cells disposed in a stack and separated by interconnects, a cathode recuperator configured to heat air provided to the stack using reaction exhaust provided from the stack, a steam generator configured to receive the reaction exhaust from the cathode recuperator and generate steam using the reaction exhaust, a hot box housing the stack, cathode recuperator, and steam generator, and a Cr filter including a porous metal and configured to remove Cr vapor species from the reaction exhaust.

Abstract: A method of making a metal alloy includes providing a molten metal alloy containing chromium, cerium and at least one of iron and nickel and providing an oxidizing gas and a reducing gas into the molten metal alloy to at least partially preferentially oxidize the cerium to ceria. The metal alloy may an iron or nickel based metal alloy which contains both cerium and ceria and at least 15 wt % Cr. The metal alloy may be used to form a balance of plant component for a fuel cell system.

Abstract: A fuel cell system includes fuel cells disposed in a stack and separated by interconnects, a cathode recuperator configured to heat air provided to the stack using reaction exhaust provided from the stack, a steam generator configured to receive the reaction exhaust from the cathode recuperator and generate steam using the reaction exhaust, a hot box housing the stack, cathode recuperator, and steam generator, and a Cr filter including a porous metal and configured to remove Cr vapor species from the reaction exhaust.

Abstract: A method of operating a fuel cell system includes providing a fuel cell stack containing a plurality of fuel cells and interconnects, and first and second ceramic side baffles located on opposing sides of the fuel cell stack, and applying an electrical potential to an outer surface of at least one of the first and the second ceramic side baffles, such that the electrical potential is equal to or more negative than a lowest potential of any interconnect in the fuel cell stack or any electrically conductive fuel cell stack component.

Abstract: A fuel cell system includes a plurality of fuel cell segments, each segment having a plurality of fuel cells. The segments include a positive terminal having a positive voltage with respect to ground and a negative terminal. The fuel cell system also includes at least one component electrically connecting the negative terminal to ground, the at least one component configured to decrease a surge current through the segments.

Abstract: A method of operating a fuel cell system includes providing a fuel cell stack containing a plurality of fuel cells and interconnects, and first and second ceramic side baffles located on opposing sides of the fuel cell stack, and applying an electrical potential to an outer surface of at least one of the first and the second ceramic side baffles, such that the electrical potential is equal to or more negative than a lowest potential of any interconnect in the fuel cell stack or electrically conductive fuel cell stack or column component.

Abstract: A method of treating a fuel cell system balance of plant component including coating the component with a slurry comprising CeO2, Y2O3 and/or HfO2 particles in a liquid, thereby forming a slurry coated component, followed by removing the liquid.

Abstract: A coated interconnect for a solid oxide fuel cell including an interconnect substrate comprising iron and chromium and a first metal oxide coating formed over an air side of the interconnect substrate. The first metal oxide coating is formed from powder particles, wherein substantially all the powder particles have a particle size less than 22 microns.

Abstract: A coated interconnect for a solid oxide fuel cell including an interconnect substrate comprising iron and chromium and a first metal oxide coating formed over an air side of the interconnect substrate. The first metal oxide coating is formed from powder particles, wherein substantially all the powder particles have a particle size less than 22 microns.

Abstract: This invention relates to thermal spray coatings on a metal or non-metal substrate. The thermal spray coating comprises a partially or fully stabilized ceramic coating, e.g., yttria stabilized zirconia coating, and has sufficiently high thermodynamic phase stability to provide corrosion and/or erosion resistance to the substrate. This invention also relates to methods of protecting metal and non-metal substrates by applying the thermal spray coatings. The coatings are useful, for example, in the protection of integrated circuit manufacturing equipment, internal chamber components, and electrostatic chuck manufacture.

Abstract: An impervious corrosion resistance nickel-chromium coating on a metallic substrate, such as an iron-containing alloy substrate that protects the substrate from a corrosive media and the process for producing the coating on the substrate.

Abstract: An impervious corrosion resistance nickel-chromium coating on a metallic substrate, such as an iron-containing alloy substrate that protects the substrate from a corrosive media and the process for producing the coating on the substrate.