Abstract: A fuel cell includes a cell having a solid oxide electrolyte between electrodes. The cell has a first coefficient of thermal expansion. A metallic support is in electrical connection with one of the electrodes. The metallic support includes a metal substrate and a compliant porous nickel layer that is bonded to the metal substrate between the cell and the metal substrate. The metal substrate has a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell. The metal substrate has a first stiffness and the compliant porous nickel layer has a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate.

Abstract: A bipolar plate (30) for use in a fuel cell stack (10) includes one or more first metal layers (40a) having a tendency to grow an electrically passive layer in the presence of a fuel cell reactant gas and one or more second metal layers (40b) directly adjacent the one or more first metal layers (40a). The second metal layer has a tendency to resist growing any oxide layer in the presence of the fuel cell reactant gas to maintain a threshold electrical conductivity. The second metal layer also has a section for contacting an electrode (12, 14) and providing an electrically conductive path between the electrode (12, 14) and the first metal layer.

Abstract: A fuel cell includes a cell having a solid oxide electrolyte between electrodes. The cell has a first coefficient of thermal expansion. A metallic support is in electrical connection with one of the electrodes. The metallic support includes a metal substrate and a compliant porous nickel layer that is bonded to the metal substrate between the cell and the metal substrate. The metal substrate has a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell. The metal substrate has a first stiffness and the compliant porous nickel layer has a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate.

Abstract: A bipolar plate (30) for use in a fuel cell stack (10) includes one or more first metal layers (40a) having a tendency to grow an electrically passive layer in the presence of a fuel cell reactant gas and one or more second metal layers (40b) directly adjacent the one or more first metal layers (40a). The second metal layer has a tendency to resist growing any oxide layer in the presence of the fuel cell reactant gas to maintain a threshold electrical conductivity. The second metal layer also has a section for contacting an electrode (12, 14) and providing an electrically conductive path between the electrode (12, 14) and the first metal layer.