Glass–Zirconia Composites as Seals for Solid Oxide Cells: Preparation, Properties, and Stability over Repeated Thermal Cycles

This study focuses on the preparation and characterization of composite gaskets designed for the sealing of the solid oxide cell stacks operating below 700 °C. The seals were fabricated with the addition of various amounts (10–90 wt.%) of 3 mol.% yttria partially stabilized zirconia to a BaO-Al(2)O(3)-CaO-SiO(2) glass matrix. The sample gaskets in the form of thin frames were shaped by tape casting. The quality of the junctions between the composites and Crofer 22APU steel commonly used as an SOC interconnect was evaluated after thermal treatment of heating to 710 °C, then cooling to the working temperature of around 620 °C and then leaving them for 10h in an air atmosphere, before cooling to room temperature. The samples were also studied after 3, 5, and 10 thermal cycles to determine the changes in microstructure and to evaluate the porosity and possible crystallization of the glass phase. The compression of the seals was calculated on the basis of differences in thickness before and after thermal treatment. The influence of zirconia additions on the mechanical properties of the seals was studied. The experimental results confirmed that glass–ceramic composites are promising materials for gaskets in SOC stacks. The most beneficial properties were obtained for a composite containing 40 wt.% of YSZ.