This title appears in the Scientific Report : 2009 

Entwicklung und Herstellung von foliengegossenen, anodengestützten Festoxidbrennstoffzellen
Schafbauer, Wolfgang (Corresponding author)
Werkstoffsynthese und Herstellungsverfahren; IEK-1
Jülich Forschungszentrums Jülich GmbH Zentralbibliothek, Verlag 2009
VI, 184 S.
Univ. Bochum, Diss., 2009
Dissertation / PhD Thesis
Rationelle Energieumwandlung
Schriften des Forschungszentrums Jülich : Energie & Umwelt / Energy & Environment 66
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Solid oxide fuel cells offer high potential in transforming the chemical energy of hydrogen or natural gas into electrical energy. Due to the high efficiency of fuel cells, lots of effort has been made in the improvement of net efficiency and in materials development during the last years. Recently, the introduction of high performance, low-cost production technologies become more and more important. At the Institute of Energy Research IEF-1 of Forschungszentrum Jülich, standard SOFCs were processed by time and work consuming methods. On the way to market entrance, product costs have to be reduced drastically. The aim of this thesis is the introduction of a high efficient low-cost processing route for the SOFC manufacturing. Therefore, the well-known and well established shaping technology tape casting was used for generating the anode substrates. As the first goal of this approach, two different tape casting slurries were developed in order to get substrates in the thickness range from 300 to 500 μm after sintering. After shaping of the substrates, sinter regimes for the different necessary coatings were adapted to the novel substrate types in order to obtain cells with high performance and strength. Therefore, the different coating technologies like screen printing and vacuum slip casting were used for cell manufacturing. The optimization of the different coating steps during cell manufacturing led to high performance SOFCs with a 10% higher power output compared to the Jülich state-of-the-art SOFC. Additional experiments verified the workability of the novel tape cast substrates for the manufacturing of near-net-shape SOFC. Finally, the novel cell types based on tape cast substrates were assembled to stacks with up to ten repeating units. Stack tests showed identical performance and degradation compared to stacks containing state-of-the-art SOFCs. Thus, the complete lifetime circle of a SOFC starting from powder preparation to stack assembly has been investigated and optimized. Next generation SOFC were developed by using tape casting as the shaping method for the necessary layers of half cells. With respect to cost effective processing methods, stepwise casting onto dried, but unfired tapes offers a lot of advantages. Furthermore, the flattening of the half cells during the sintering is not necessary, if identical electrolyte powders were used in the anode substrate and the electrolyte layer. Single cell tests with the novel tape cast half cells showed good power output.