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 intermediate solid oxide fuel cell (SOFC) stage and methods for inspecting an assembled portion of an SOFC are presented. One method for inspecting an assembled portion of an SOFC includes applying a pneumatic constraint to a fluid, where the fluid is in communication with the assembled portion of the SOFC, determining a quality control parameter of the assembled portion of the SOFC in response to the pneumatic constraint, and ascertaining health of the assembled portion of the SOFC based on the quality control parameter. The assembled portion of the SOFC includes a metallic interconnect, where the metallic interconnect includes a flow field.

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 intermediate solid oxide fuel cell (SOFC) stage and methods for inspecting an assembled portion of an SOFC are presented. One method for inspecting an assembled portion of an SOFC includes applying a pneumatic constraint to a fluid, where the fluid is in communication with the assembled portion of the SOFC, determining a quality control parameter of the assembled portion of the SOFC in response to the pneumatic constraint, and ascertaining health of the assembled portion of the SOFC based on the quality control parameter. The assembled portion of the SOFC includes a metallic interconnect, where the metallic interconnect includes a flow field.

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 oven appliance with a sensor for sensing gases in the cooking chamber is provided. One or more features and methods are provided for detecting the gas levels in the cooking chamber to determine if the cooking chamber is clean or unclean. Features for initiating and terminating an oven cleaning cycle are also provided.

Abstract: A method for preparing an electrolyte separator for an electrochemical device is described. The method includes the step of applying a beta?-alumina coating composition, or a precursor thereof, to a porous substrate, by an atmospheric, thermal spray technique. An electrochemical device is also described. Some of these devices include an anode, a cathode, and an electrolyte separator disposed between the anode and the cathode. The separator includes a thermally-sprayed layer of beta?-alumina, disposed on a porous substrate. The electrochemical device can be used as an energy storage system, or for other types of end uses.

Abstract: A method of processing a ceramic electrolyte suitable for use in a fuel cell is provided. The method comprises situating a ceramic electrolyte layer over an anode layer; and subjecting the ceramic electrolyte layer to a stress prior to operation of the fuel cell, by: exposing the top surface of the electrolyte layer to an oxidizing atmosphere and the bottom surface of the electrolyte layer to a reducing atmosphere; and heating the electrolyte layer. The stress causes a substantial increase in the number of microcracks, or in the average size of the microcracks, or in both the number of the microcracks and their average size. A solid oxide fuel cell comprising a ceramic electrolyte layer processed by the disclosed method is also provided.

Abstract: A method of processing a ceramic layer is provided. The method comprises the steps of providing a ceramic layer comprising a plurality of microcracks; infiltrating at least some of the plurality of microcracks with a liquid precursor comprising at least one oxidizable metal ion; and exposing the ceramic layer to a base having a pH value of at least about 9, so as to chemically convert the oxidizable metal ion into an oxide, thereby decreasing the porosity of the ceramic layer. A solid oxide fuel cell is provided. The solid oxide fuel cell comprises an anode; a cathode; and a ceramic electrolyte disposed between the anode and the cathode.

Abstract: A method of processing a ceramic electrolyte suitable for use in a fuel cell is provided. The method comprises situating a ceramic electrolyte layer over an anode layer; and subjecting the ceramic electrolyte layer to a stress prior to operation of the fuel cell, by: exposing the top surface of the electrolyte layer to an oxidizing atmosphere and the bottom surface of the electrolyte layer to a reducing atmosphere; and heating the electrolyte layer. The stress causes a substantial increase in the number of microcracks, or in the average size of the microcracks, or in both the number of the microcracks and their average size. A solid oxide fuel cell comprising a ceramic electrolyte layer processed by the disclosed method is also provided.

Abstract: A sensor system, and an associated method for detecting harsh environmental conditions, is provided. The sensor system includes at least one sensor having an electrical sensing element. The electrical sensing element is based on certain classes of composite materials: (a) silicon carbide (SiC); (Mo,W)5Si3C; (Mo,W)Si2; or (b) (Mo,W)5Si3C; (Mo,W)Si2; (Mo,W)5Si3. The sensor system is useful for determining harsh environmental conditions. Gasification systems, which include at least one of the sensor systems are also described.

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 detection system is presented. The detection system includes a sensing component and a data analyzer. The sensing component includes a first sensor and a second sensor in fluid communication with the first sensor. The first sensor is disposed to allow operation at a predetermined temperature T1 and is selective to a first gas species at T1 and in presence of a second gas species. The second sensor is disposed to allow operation at a temperature T2 and is sensitive to the first gas species and a second gas species at T2. Temperature T2 is lower than T1. The data analyzer is disposed to receive an output signal from the sensing component and configured to calculate concentrations of the first gas species and the second gas species based on the output signal from the sensing component. A method of calculating concentrations of gas species in a gaseous mixture is also presented.

Abstract: A method of making an electrode structure is provided. The method includes disposing an electrocatalytic material on an electrode, applying heat to the electrocatalytic material to form a volatile oxide of the electrocatalytic material, and applying a voltage to the electrode to reduce the volatile oxide to provide a number of nano-sized electrocatalytic particles on or proximate to a triple phase boundary, where the number of nano-sized electrocatalytic particles is greater on or proximate to the triple phase boundary than in an area that is not on or proximate to the triple phase boundary, and where the triple phase boundary is disposed on the electrode.

Abstract: A method of processing a ceramic layer is provided. The method comprises the steps of providing a ceramic layer comprising a plurality of microcracks; infiltrating at least some of the plurality of microcracks with a liquid precursor comprising at least one oxidizable metal ion; and exposing the ceramic layer to a base having a pH value of at least about 9, so as to chemically convert the oxidizable metal ion into an oxide, thereby decreasing the porosity of the ceramic layer. A solid oxide fuel cell is provided. The solid oxide fuel cell comprises an anode; a cathode; and a ceramic electrolyte disposed between the anode and the cathode.

Abstract: A composite ceramic electrolyte is provided. The composite ceramic electrolyte has a microstructure, which comprises a first ceramic composition comprising a plurality of nano-dimensional microcracks, and a second ceramic composition substantially embedded within at least a portion of the plurality of nano-dimensional microcracks. The first and the second compositions are different. A solid oxide fuel cell comprising a composite ceramic electrolyte having such a microstructure is provided. A method of making a composite ceramic electrolyte is also described.

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.