Abstract: A method for making a solid oxide fuel cell component includes depositing a cathode material directly onto a metallic interconnect. The interconnect may comprise stainless steel or another suitable metal. The cathode material may comprise a ceramic. Examples of cathode materials are yttria-stabilized zirconia (YSZ) and mixtures of YSZ with other ceramics such as lanthanum strontium manganate. The cathode material may be deposited by plasma spraying. A pore former may be plasma sprayed together with the cathode material to provide a porous cathode. Electrolyte and anode materials may be deposited on the cathode material also by plasma spraying. Plasma conditions may be selected to provide a dense electrolyte layer.

Abstract: A method for making a densified ceramic layer comprises plasma spraying a layer of the ceramic onto a substrate; spin-coating the plasma-sprayed layer with a sol, and firing the spin-coated ceramic layer. The method may be applied in producing layers of yttria stabilized zirconia (YSZ) having application as electrolyte layers for solid oxide fuel cells or thermal barrier coatings, for example. The firing may be performed at a relatively low temperature such as 650° C. or even below. A method for enhancing electrochemical properties of an interface involving a layer of YSZ or other ceramic comprises spin-coating or otherwise impregnating the layer with a sol and heating the spin-coated layer.

Abstract: A method for the rapid production of electrode structures such as Cu-SDC anodes for use in direct oxidation solid oxide fuel cells involves co-depositing a copper-containing material and a ceramic by plasma spraying to form a coating on a substrate. Layers of CuO-SDC have been co-deposited by air plasma spraying, followed by in-situ reduction of the CuO to Cu in the anodes. Materials having catalytic properties, such as cobalt, may also be incorporated in the structures. Controlled compositional or microstructural gradients may be applied to optimize the microstructure and composition of the coatings.

Abstract: A technique for determining properties such as Young's modulus, coefficient of thermal expansion, and residual stress of individual layers within a multi-layered sample is presented. The technique involves preparation of a series of samples, each including one additional layer relative to the preceding sample. By comparison of each sample to a preceding sample, properties of the topmost layer can be determined, and residual stress at any depth in each sample, resulting from deposition of the top layer, can be determined.