Abstract: A bonding layer, disposed between an interconnect layer and an electrode layer of a solid oxide fuel cell article, may be formed from a yttria stabilized zirconia (YSZ) powder having a monomodal particle size distribution (PSD) with a d50 that is greater than about 1 ?m and a d90 that is greater than about 2 ?m.

Abstract: A bonding layer, disposed between an interconnect layer and an electrode layer of a solid oxide fuel cell article, may be formed from a yttria stabilized zirconia (YSZ) powder having a monomodal particle size distribution (PSD) with a d50 that is greater than about 1 ?m and a d90 that is greater than about 2 ?m.

Abstract: A raw material powder for forming a layer of a solid oxide fuel cell (SOFC) article includes a broad particle size distribution (BPSD) defined by plotted curve of frequency versus diameter of the raw material powder may be characterized as having a first standard deviation including at least about 78% to at least about 99% of a total content of particles of the raw material powder. The plotted curve of the BPSD may also be characterized as having a first maximum value and a first minimum value, wherein the difference between the first maximum value and first minimum value is not greater than about 8%.

Abstract: The present disclosure relates to solid oxide fuel cells, and particularly raw powder materials which form a layer in a solid oxide fuel. The raw powder materials include an ionic conductor powder material; and an electronic conductor powder material. The ratio of an average particle diameter of the ionic conductor powder material to an average particle diameter of the electronic conductor powder material is greater than about 1:1, and an average particle diameter of at least one of the electronic conductor powder material or the ionic conductor powder material is coarse.

Abstract: A method of forming a solid oxide fuel cell (SOFC) article includes providing a green electrode layer formed by a freeze-casting process and forming a green SOFC unit cell. The green SOFC unit cell includes a green electrolyte layer, a green cathode layer overlying the electrolyte layer, a green interconnect layer, and a green anode layer disposed between the green electrolyte layer and the interconnect layer. The method includes sintering the green SOFC unit cell in a single sintering process to form a sintered SOFC unit cell.

Abstract: A solid oxide fuel cell (SOFC) article including a SOFC unit cell having a functional layer of an average thickness of not greater than about 100 ?m, wherein the functional layer has a first type of porosity having a vertical orientation, and the first type of porosity has an aspect ratio of length:width, the width substantially aligned with a dimension of thickness of the functional layer.

Abstract: A bonding layer, disposed between an interconnect layer and an electrode layer of a solid oxide fuel cell article, may be formed from a yttria stabilized zirconia (YSZ) powder having a monomodal particle size distribution (PSD) with a d50 that is greater than about 1 ?m and a d90 that is greater than about 2 ?m.

Abstract: A method for forming a solid oxide fuel cell (SOFC) article includes forming a SOFC unit cell in a single, free-sintering process, wherein the SOFC unit cell is made of an electrolyte layer, an interconnect layer, a first electrode layer disposed between the electrolyte layer and the interconnect layer. The electrolyte layer of the SOFC unit cell is in compression after forming.

Abstract: A solid oxide fuel cell electrolyte is fabricated by combining an yttria-stabilized zirconia powder with ?-Al2O3 having a d50 particle size in a range of between about 10 nm and about 200 nm and Mn2O3 to form an electrolyte precursor composition, and then sintering the electrolyte precursor composition to thereby form the electrolyte. The ?-Al2O3 and Mn2O3 can be present in the electrolyte precursor composition in an amount in a range of between about 0.25 mol % and about 5 mol %. The electrolyte can be a component of a solid oxide fuel cell of the invention.

Abstract: An interconnect material is formed by combining a lanthanum-doped strontium titanate with an aliovalent transition metal to form a precursor composition and sintering the precursor composition to form the interconnect material. The aliovalent transition metal can be an electron-acceptor dopant, such as manganese, cobalt, nickel or iron, or the aliovalent transition metal can be an electron-donor dopant, such as niobium or tungsten. A solid oxide fuel cell, or a strontium titanate varistor, or a strontium titanate capacitor can include the interconnect material that includes a lanthanum-doped strontium titanate that is further doped with an aliovalent transition metal.

Abstract: A solid oxide fuel cell electrolyte is fabricated by combining an yttria-stabilized zirconia powder with ?-Al2O3 having a d50 particle size in a range of between about 10 nm and about 200 nm and Mn2O3 to form an electrolyte precursor composition, and then sintering the electrolyte precursor composition to thereby form the electrolyte. The ?-Al2O3 and Mn2O3 can be present in the electrolyte precursor composition in an amount in a range of between about 0.25 mol % and about 5 mol %. The electrolyte can be a component of a solid oxide fuel cell of the invention.

Abstract: A solid oxide fuel cell (SOFC) includes a plurality of sub-cells. Each sub-cell includes a first electrode in fluid communication with a source of oxygen gas, a second electrode in fluid communication with a source of a fuel gas, and a solid electrolyte between the first electrode and the second electrode. The SOFC further includes an interconnect between the sub-cells. The interconnect includes a first layer in contact with the first electrode of each sub-cell, and a second layer in contact with the second electrode of each sub-cell. The first layer includes at least one material selected from the group consisting of a doped M-ferrite based perovskite, a doped M?-ferrite based perovskite, a doped MM?-ferrite based perovskite and a doped M?-chromite based perovskite, wherein M is an alkaline earth metal and M? is a rare earth metal. The second layer includes a doped M?-titanate based perovskite, wherein M? is an alkaline earth metal.