Advanced 3D Fabrication of Energy Conversion Device Structures

The aim of this project was to begin the development of a new three-dimensional materials fabrication capability, Additive Layer Manufacturing (ALM).[1, 2] This initial 6 months of support allowed us to assess the feasibility of printing high-quality ceramic layers. In particular, a process was developed for printing layers of Yttria-Stabilized Zirconia (YSZ). This required the development of stable YSZ colloidal suspensions with appropriate particle size distribution and solids loading, along with surface tension and viscosity values that allow for inkjet printing. Furthermore, software was developed that provides greater control over the printing process than what is available in commercial document printer driver software. YSZ deposition rates were characterized. After some process development, YSZ layers printed onto NiO-YSZ supports and then fired at elevated temperatures were found to be of uniform thickness and high density. After application of a (La,Sr)(Fe,Co)O3 (LSFC) cathode, LSCF/YSZ/Ni-YSZ structures were tested at elevated temperature as a solid oxide fuel cell; the near-theoretical open-circuit potential observed is indicative of a dense pore-free electrolyte layer. Based on this initial success, next steps will be to develop inks/processes for depositing other cell active materials, leading to a capability to print entire electrochemical cells, and eventually to print novel 3D electrochemical cell structures. We are seeking further support, both here and in Denmark, for this continuing R&D effort.