Fabrication and Characterization of a Composite Ni-SDC Fuel Cell Cathode Reinforced by Ni Foam

High-temperature fuel cells (namely, molten carbonate and solid oxide; MCFCs and SOFCs) require the cathode to be designed to maximize oxygen catalytic reduction, oxygen ion transport, electrical conductivity, and gas transport. This then leads to the optimization of the volume fraction and morphology of phases, as they are a pathway for electrons, ions, and gases to be continuous and self-interpenetrating. Apart from the functional properties, the cathode must be mechanically stable to prevent cracking during fuel cell assembly and operation. The manufacturing process of the composite cathode was optimized to meet such requirements in this research work. The tape casting technique and further firing process were used to fabricate the cathodes. The slurry for the green tape was composed of nickel (Ni), cerium oxide doped with samarium oxide (SDC), water (solvent), and an organic binder (which becomes pore space after firing). Each of these elements is necessary for the effective transport of specific species: electrons, oxygen, ions, and gas particles, respectively. Moreover, the nickel foam was embedded into the powder-based structure to improve mechanical strength. The study involved many technological issues, such as the effect of the SDC fraction on the cathode microstructure, mechanical strength, and chemical stability at high temperatures, and also involved environmental issues.