Abstract: Systems and methods for sintering and conditioning fuel cell stacks utilizing channel guides, baffles, and internal compression systems are provided. Sintering and conditioning may be performed utilizing a fuel cell column cartridge assembly and fuel cell stacks may be sintered and conditioned at the system level during the same annealing cycle on the same support.

Abstract: Various embodiments provide systems and methods for detecting defects in components of a fuel cell. Embodiment methods and systems for detecting a defect in an interconnect for a fuel cell system include thermally exciting the interconnect using optical radiation and/or inductive stimulation, detecting a thermal response of the interconnect, and based on the thermal response, determining the presence or absence of a defect in the interconnect, such as a lateral or through crack in the interconnect.

Abstract: Systems and methods for fuel cell stack part serialization and tracking. In an embodiment, a barcode may be applied to a fuel cell stack part which may identify the fuel cell stack part. In an embodiment, the barcode may be applied as ink on a green fuel cell stack part prior to sintering. In an embodiment, a portion of a fuel cell stack part may be imaged and pattern recognition techniques may be utilized to identify the fuel cell stack part based on the unique features of fuel cell stack part. In an embodiment, portion of a fuel cell stack part may be measured to generate one or more series of unique volume/area values and one or more series of unique volume/area values may be utilized to identify the fuel cell stack part.

Abstract: A measurement device for measuring voltages along a linear array of voltage sources, such as a fuel cell stack, includes at least one movable contact or non-contact voltage probe that measures a voltage of an array element.

Abstract: Methods and systems for measuring a property of a component of a fuel cell system include performing a three-dimensional optical scan of at least a portion of a surface of the component to produce a three-dimensional representation of the topography of the at least a portion of the surface and measuring at least one property of the component based on the three-dimensional representation. Further embodiments include systems and methods for measuring dimensions of a fuel cell component using a line scan imaging device and/or a matrix camera.

Abstract: Methods for fabricating an interconnect for a fuel cell stack include placing a compressed metal powder interconnect on a porous support, and sintering the interconnect in the presence of a non-oxidizing gas. The method may further include placing the sintered interconnect on a porous support, and oxidizing the interconnect in the presence of flowing air, or placing the sintered interconnect on a dense, non-porous support, and oxidizing the interconnect in the presence of a gas comprising pure oxygen or an oxygen/inert gas mixture that is substantially nitrogen-free.

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 operating a fuel cell system includes introducing a fuel mixture comprising hydrogen, fuel, and steam at a fuel inlet of the fuel cell system, and operating the fuel cell system to generate electricity. A ratio of hydrogen to carbon from fuel (H2:Cfuel) in the fuel mixture is within a range of 0.25:1 to 3:1, inclusive; and a ratio of steam to carbon (S:C) in the fuel mixture is less than 2:1.

Abstract: Methods for fabricating an interconnect for a fuel cell stack include placing a compressed metal powder interconnect on a porous support, and sintering the interconnect in the presence of a non-oxidizing gas. The method may further include placing the sintered interconnect on a porous support, and oxidizing the interconnect in the presence of flowing air, or placing the sintered interconnect on a dense, non-porous support, and oxidizing the interconnect in the presence of a gas comprising pure oxygen or an oxygen/inert gas mixture that is substantially nitrogen-free.

Abstract: Various embodiments provide systems and methods for detecting defects in components of a fuel cell. Embodiment methods and systems include directing acoustic energy into the component, detecting acoustic energy from the component, analyzing a characteristic of the detected acoustic energy, and based on the analyzing, determining the presence or absence of a defect in the component.

Abstract: Systems and methods are provided for fuel cell stack heat treatment. An eductor may be used to recycle air into the air inlet stream or to recycle fuel into the fuel inlet stream. An eductor may also be used to exhaust air away from the furnace. The stack heat treatment may include stack sintering or conditioning. The conditioning may be conducted without using externally supplied hydrogen.

Abstract: Systems and methods for sintering and conditioning fuel cell stacks utilizing channel guides, baffles, and internal compression systems are provided. Sintering and conditioning may be performed utilizing a fuel cell column cartridge assembly and fuel cell stacks may be sintered and conditioned at the system level during the same annealing cycle on the same support.

Abstract: Systems and methods for sintering and conditioning fuel cell stacks utilizing channel guides, baffles, and internal compression systems are provided. Sintering and conditioning may be performed utilizing a fuel cell column cartridge assembly and fuel cell stacks may be sintered and conditioned at the system level during the same annealing cycle on the same support.

Abstract: A measurement device for measuring voltages along a linear array of voltage sources, such as a fuel cell stack, includes at least one movable contact or non-contact voltage probe that measures a voltage of an array element.

Abstract: A measurement device for measuring voltages along a linear array of voltage sources, such as a fuel cell stack, includes at least one movable contact or non-contact voltage probe that measures a voltage of an array element.

Abstract: A fuel cell interconnect includes a first side containing a first plurality of channels and a second side containing a second plurality of channels. The first and second sides are disposed on opposite sides of the interconnect. The first plurality of channels are configured to provide a serpentine fuel flow field while the second plurality of channels are configured to provide an approximately straight air flow field.

Abstract: Various embodiments include a fuel cell stack seal application method including the step of applying a seal paste to a fuel cell, placing the fuel cell in a fuel cell stack, and thermally treating the fuel cell stack to set the seal paste into a seal. Further embodiments include applying the seal paste to an interconnect using stencil printing.

Abstract: An interconnect for a fuel cell stack includes a first plurality of ribs extending from a first major surface of the interconnect and defining a first plurality of gas flow channels between the ribs, the ribs extending between a first rib end and a second rib end and having a tapered profile in a vertical dimension, perpendicular to the first major surface of the interconnect, proximate at least one of the first rib end and the second rib end, wherein the ribs comprise a flat upper surface and rounded edges between the flat upper surface and the adjacent gas flow channels, the rounded edges having a first radius of curvature, and wherein the gas flow channels comprise a rounded surface having a second radius of curvature, different from the first radius of curvature.

Abstract: Various embodiments include a fuel cell stack seal application method including the step of applying a seal paste to a fuel cell, placing the fuel cell in a fuel cell stack, and thermally treating the fuel cell stack to set the seal paste into a seal. Further embodiments include applying the seal paste to an interconnect using stencil printing.

Abstract: Systems and methods for fuel cell stack part serialization and tracking. In an embodiment, a barcode may be applied to a fuel cell stack part which may identify the fuel cell stack part. In an embodiment, the barcode may be applied as ink on a green fuel cell stack part prior to sintering. In an embodiment, a portion of a fuel cell stack part may be imaged and pattern recognition techniques may be utilized to identify the fuel cell stack part based on the unique features of fuel cell stack part. In an embodiment, portion of a fuel cell stack part may be measured to generate one or more series of unique volume/area values and one or more series of unique volume/area values may be utilized to identify the fuel cell stack part.