Abstract: A fuel cell assembly includes a fuel cell stack including a plurality of fuel cells, an incoming oxidizing gas flow path configured to deliver an oxidizing gas to the plurality of fuel cells, and a chromium-getter material located in the incoming oxidizing flow path. A fuel cell includes an electrolyte, a cathode electrode on a first side of the electrolyte, an anode electrode on a second side of the electrolyte, and a chromium-getter material on the cathode electrode.

Abstract: Systems and methods for testing a fuel cell stack include a vacuum source, a test head including at least one isolated vacuum plenum configured to be positioned in fluid communication with a first portion of the fuel cell stack, the isolated vacuum plenum in fluid communication with the vacuum source, and a detector in fluid communication with the at least one isolated vacuum plenum for detecting the presence of a particular constituent of a fluid provided in a second portion of the fuel cell stack, where the second portion of the fuel cell stack is separated from the first portion of the fuel cell stack by at least one of an electrolyte and a fuel cell seal.

Abstract: A solid oxide fuel cell (SOFC) includes a solid oxide electrolyte with a zirconia-based ceramic, an anode electrode, and a cathode electrode that includes a ceria-based ceramic component and an electrically conductive component. Another SOFC includes a solid oxide electrolyte containing a zirconia-based ceramic, an anode electrode, and a cathode electrode that includes an electrically conductive component and an ionically conductive component, in which the ionically conductive component includes a zirconia-based ceramic containing scandia and at least one of ceria, ytterbia and yttria.

Abstract: A fuel cell column includes termination plates, fuel cell stacks disposed between the termination plates, and fuel manifolds disposed between the fuel cell stacks. The fuel cell stacks include fuel cells, interconnects disposed between the fuel cells, and end plates disposed on opposing ends of the fuel cell stacks. At least one of the termination plates and/or the fuel manifold may include first and second separate pieces separated by an expansion zone. The fuel cell stack may also include one or more buffer layers and/or seals configured to reduce CTE differences of components of the fuel cell stack.

Abstract: A solid oxide fuel cell (SOFC) includes a solid oxide electrolyte with a zirconia-based ceramic, an anode electrode, and a cathode electrode that includes a ceria-based ceramic component and an electrically conductive component. Another SOFC includes a solid oxide electrolyte containing a zirconia-based ceramic, an anode electrode, and a cathode electrode that includes an electrically conductive component and an ionically conductive component, in which the ionically conductive component includes a zirconia-based ceramic containing scandia and at least one of ceria, ytterbia and yttria.

Abstract: A solid oxide fuel cell, system including the same, and method of using the same, the fuel cell including an electrolyte disposed between an anode and a cathode. The anode includes a first layer including a metallic phase and a ceramic phase, and a second layer including a metallic phase. The metallic phase of the second layer includes a metal catalyst and a dopant selected from Al, Ca, Ce, Cr, Fe, Mg, Mn, Nb, Pr, Ti, V, W, or Zr, any oxide thereof, or any combination thereof. The second layer may also include a ceramic phase including ytterbia-ceria-scandia-stabilized zirconia (YCSSZ).

Abstract: A fuel cell column includes termination plates, fuel cell stacks disposed between the termination plates, and fuel manifolds disposed between the fuel cell stacks. The fuel cell stacks include fuel cells, interconnects disposed between the fuel cells, and end plates disposed on opposing ends of the fuel cell stacks. At least one of the termination plates and/or the fuel manifold may include first and second separate pieces separated by an expansion zone. The fuel cell stack may also include one or more buffer layers and/or seals configured to reduce CTE differences of components of the fuel cell stack.

Abstract: A seal composition includes a first alkaline earth metal oxide, a second alkaline earth metal oxide which is different from the first alkaline earth metal oxide, aluminum oxide, and silica in an amount such that molar percent of silica in the composition is at least five molar percent greater than two times a combined molar percent of the first alkaline earth metal oxide and the second alkaline earth metal oxide. The composition is substantially free of phosphorus oxide. The seal composition forms a glass ceramic seal which includes silica containing glass cores located in a crystalline matrix comprising barium aluminosilicate, and calcium aluminosilicate crystals located in the glass cores.

Abstract: Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.

Abstract: A method of operating a solid oxide fuel cell (SOFC) system which contains a plurality of SOFCs having cermet anode electrodes includes operating the SOFC system above 760° C. to generate electricity and intentionally oxidizing the cermet anode electrodes at a temperature of at least 760° C. when the SOFC system stops operating to generate electricity.

Abstract: A seal composition includes a first alkaline earth metal oxide, a second alkaline earth metal oxide which is different from the first alkaline earth metal oxide, aluminum oxide, and silica in an amount such that molar percent of silica in the composition is at least five molar percent greater than two times a combined molar percent of the first alkaline earth metal oxide and the second alkaline earth metal oxide. The composition is substantially free of phosphorus oxide. The seal composition forms a glass ceramic seal which includes silica containing glass cores located in a crystalline matrix comprising barium aluminosilicate, and calcium aluminosilicate crystals located in the glass cores.

Abstract: Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.

Abstract: A method of making an interconnect for a solid oxide fuel cell stack includes contacting an interconnect powder located in a die cavity with iron, the interconnect powder including a chromium and iron, compressing the interconnect powder to form an interconnect having ribs and fuel channels on a first side of the interconnect, such that the iron is disposed on tips of the ribs; and sintering the interconnect, such that the iron forms an contact layer on the tips of the ribs having a higher iron concentration than a remainder of the interconnect. A glass containing cathode contact layer having a glass transition temperature of 900° C. or less may be located over the rib tips on the oxidant side of the interconnect.

Abstract: A chromium-iron interconnect includes at least one of Fe rich regions in the interconnect and carbon in the interconnect.

Abstract: A method for testing a fuel cell stack includes providing a fluid, such as an ammonia-containing fluid, in a first reactant flow path in a first portion of the fuel cell stack, detecting the presence of the fluid using a detector, such as an ammonia detector, positioned within or adjacent to a second portion of the fuel cell stack that is separated from the first portion of the fuel cell stack and determining the presence of a defect in the stack based on detecting the presence of the fluid. Further embodiments relate to testing a fuel cell stack using a microphone that detects an audio signal indicative of a stack defect.

Abstract: A fuel cell assembly includes a fuel cell stack including a plurality of fuel cells, an incoming oxidizing gas flow path configured to deliver an oxidizing gas to the plurality of fuel cells, and a chromium-getter material located in the incoming oxidizing flow path. A fuel cell includes an electrolyte, a cathode electrode on a first side of the electrolyte, an anode electrode on a second side of the electrolyte, and a chromium-getter material on the cathode electrode.

Abstract: A solid oxide fuel cell (SOFC) includes a cathode electrode, a solid oxide electrolyte and an anode electrode containing a first portion having a cermet containing a nonzero volume percent of a nickel containing phase and a nonzero volume percent of a ceramic phase and a second portion having a cermet containing a nonzero volume percent of a nickel containing phase and a nonzero volume percent of a ceramic phase, such that the first portion is located between the electrolyte and the second portion. The SOFC is an electrolyte-supported SOFC and the first portion of the anode electrode contains a lower ratio of the nickel containing phase to the ceramic phase than the second portion of the anode electrode. The first portion of the anode electrode has a porosity of 5-30 volume percent and the second portion of the anode electrode has a porosity of 31-60 volume percent.

Abstract: A solid oxide fuel cell (SOFC) includes a cathode electrode, a solid oxide electrolyte, and an anode electrode. The electrolyte and/or electrode composition includes zirconia stabilized with (i) scandia, (ii) ceria, and (iii) at least one of yttria and ytterbia. The composition does not experience a degradation of ionic conductivity of greater than 15% after 4000 hrs at a temperature of 850° C.

Abstract: Various embodiments of a reactant feed and return assembly, such as an anode splitter plate (ASP), are provided for facilitating reactant feed and exhaust flow in a solid oxide fuel cell (SOFC) stack system. Embodiments include a reactant feed and return assembly including at least a first portion formed of a chromium-based alloy, such as a chromium-iron alloy, having a similar coefficient of thermal expansion as other SOFC components and may therefore reduce internal stress in an SOFC stack. Methods for making an a reactant feed and return assembly comprising a chromium-based alloy are also provided.

Abstract: A solid oxide fuel cell (SOFC) includes a cathode electrode, a solid oxide electrolyte, and an anode electrode. The electrolyte includes yttria stabilized zirconia and scandia stabilized zirconia, such as scandia ceria stabilized zirconia.