Abstract: An solid oxide fuel cell stack having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between a metallic layer and a glass layer are disclosed. The solid oxide fuel cell stack has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: An article having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between a metallic layer and a glass layer are disclosed. The article has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: A solid oxide fuel cell stack having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between the metallic layer and the glass layer are disclosed. The solid oxide fuel cell stack has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: An article having a metallic layer and a glass layer, and a method for preventing or reducing a chemical reaction between a metallic layer and a glass layer are disclosed. The article has a barrier layer disposed between the metallic layer and the glass layer. The barrier layer includes alumina and a phosphate. The phosphate includes an aluminum dihydrogen phosphate, an aluminum-containing phosphate, a phosphate of an element of the metallic layer, a phosphate of an element of the glass layer, or combinations thereof. The method includes disposing a barrier layer between the metallic layer and the glass layer.

Abstract: An electrically-conductive layer of material having a composition comprising lanthanum and strontium is described. The material is characterized by a microstructure having bimodal porosity. Another concept in this disclosure relates to a solid oxide fuel cell attached to at least one cathode interconnect by a cathode bond layer. The bond layer includes a microstructure having bimodal porosity. A fuel cell stack which incorporates at least one of the cathode bond layers is also described herein, along with related processes for forming the cathode bond layer.

Abstract: A solid oxide fuel cell (SOFC) manifold and interconnect structure includes a manifold that has a dense and hermetic planar surface that is impervious to fuel gas used with the corresponding SOFC. A porous material includes a permeable planar surface that is in lateral contact with the planar surface of the manifold to form an electrode interconnect. The exposed surface of the junction between the dense and hermetic planar surface and the permeable planar surface is substantially flat and devoid of discontinuities, corners and seams. The dense and hermetic planar surface, the permeable planar surface and the exposed surface of the junction lay in a single common plane suitable for thermal deposition of electrode and electrolyte layers.

Abstract: An electrically-conductive layer of material having a composition comprising lanthanum and strontium is described. The material is characterized by a microstructure having bimodal porosity. Another concept in this disclosure relates to a solid oxide fuel cell attached to at least one cathode interconnect by a cathode bond layer. The bond layer includes a microstructure having bimodal porosity. A fuel cell stack which incorporates at least one of the cathode bond layers is also described herein, along with related processes for forming the cathode bond layer.

Abstract: Systems and methods for high performing in-situ SOFC cathodes, demonstrating self-improved performance over time. Exemplary embodiments include a SOFC including an electrolyte layer, an anode coupled to the electrolyte layer and a cathode coupled to the electrolyte layer, wherein the anode is prepared by applying an anode contact layer to the anode layer and applying anode bond paste to the anode contact layer, wherein the cathode is prepared by screen printing a cathode layer on the electrolyte with or without a barrier layer, and applying cathode bond paste to the dried cathode layer and drying the cathode bond paste in an oven.