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: Various embodiments include methods of fabricating an interconnect for a fuel cell stack. Methods for controlled pre-oxidation of an interconnect include oxidizing in a nitride-inhibiting environment to inhibit the formation of nitrides.

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: Various embodiments include interconnects for a fuel cell stack that includes a first support frame having a first surface that is configured to be secured to a first surface of a fuel cell. A gas flow separator section is secured to a second surface of the first support frame, opposite the first surface of the first support frame. A second support frame is secured to a second surface of a second fuel cell, opposite the first surface of the first fuel cell. The first and second support frames have a coefficient of thermal expansion (CTE) that substantially matches the CTE of the electrolyte material of the fuel cells, and the gas flow separator section has a CTE that does not substantially match a CTE of an electrolyte material of the fuel cells.

Abstract: A method of making a solid oxide fuel cell (SOFC) includes providing a solid oxide electrolyte and depositing at least one electrode on the electrolyte by PVD, such as sputtering. A method of making an interconnect for a fuel cell stack includes providing an electrically conductive interconnect, and depositing a layer on the interconnect by PVD, such as depositing a LSM barrier layer by sputtering. The SOFC and the interconnect may be located in the same fuel cell stack.

Abstract: Methods of fabricating an interconnect for a fuel cell stack include providing a powder in a die cavity of a powder press apparatus, where the powder includes at least one of a pre-alloyed powder and a pre-sintered powder, compressing the powder in the die cavity of the powder press apparatus using high velocity compaction to form a pressed powder interconnect, and incorporating the pressed powder interconnect into a fuel cell stack, wherein the pressed powder interconnect is incorporated into the fuel cell stack without first sintering the pressed powder interconnect.

Abstract: A method of making a solid oxide fuel cell (SOFC) includes providing a solid oxide electrolyte and depositing at least one electrode on the electrolyte by PVD, such as sputtering. A method of making an interconnect for a fuel cell stack includes providing an electrically conductive interconnect, and depositing a layer on the interconnect by PVD, such as depositing a LSM barrier layer by sputtering. The SOFC and the interconnect may be located in the same fuel cell stack.