Thermal Spray Multilayer Ceramic Structures with Potential for Solid Oxide Cell Applications

The objective of this paper is to manufacture free-standing solid oxide cells (SOCs) through the atmospheric plasma spray process (APS), without aid a metallic support nor need for post-process heating treatment. A five-layered cell was fabricated. Fused and crushed yttria-stabilized zirconia (YSZ) powder in 5–22 μm particle size range used order achieve dense electrolyte layer, yet still permitting satisfactory ionic diffusivity. Nickel (NiO) that obtained by in-house flame (FS) oxidation pure nickel (Ni) mixed sprayed with original Ni-YSZ feedstock, so as increase porosity content supporting electrode. Two transition layers were sprayed, first between electrode (25% (Ni/NiO)–75% YSZ) second at end interface (50% YSZ–50% lanthanum strontium manganite (LSM)). purpose intercalation these facilitate motion also eliminate thermal expansion mismatches. All as-sprayed separately tested an developed acetone permeability comparative test (APCT). Electrodes adequate (25–30%) obtained. Concerning electrolytes, relatively thick (150–200 µm) derived from fused YSZ found be impermeable acetone, while thinner counterparts less than 100 µm showed low degree permeability, which attributed mostly existent microcracks insufficient interparticle cohesion, rather interconnected porosity.