Integration of Ni-GDC layer on a NiCrAl metal foam for SOFC application

Metal supported Solid Oxide Fuel Cells (MS-SOFCs) have attracted considerable interest for their increasedrobustness and tolerance to redox and thermal cycling and their cheaper production costs. One of themain issue for the development of the MS-SOFC is the integration of the metallic-ceramic electrode onto ametal substrate using cheaper and easily scalable manufacturing techniques. In this study, the integrationof a Ni-GDC anode layer on NiCrAl metal support with a porosity higher than 80 vol.% by conventionaltechnique was successfully addressed. A defect free electrode of 5 × 5 cm2 of dimensions with smoothedsurface (necessary for the electrolyte deposition) was obtained through a careful design of the thicknessand the composition of the Ni-GDC layers and using (first time for this application) the stencil printingapproach. The roughness of the final electrodic layer was comparable to the ones reported for layerdeposited on flat/less porous ceramic substrates.