Development of coatings for solid oxide fuel cell interconnects

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Interconnects for solid oxide fuel cells are made of high chromium alloy to achieve adequate corrosion resistance at 800 C and and are coated on the cathode side by strontium-doped lanthanum manganite perovskite (LSM) as a barrier against chromium evaporation. A significant problem that remains is the very high cost associated with the air plasma spray (APS) coating process. The contributing cost factors are: i) the high price of the raw material (around $100/kg), ii) the low deposition efficiency (typically 30%-40% utilization), iii) the high capital equipment cost and iv) the relatively low output of the APS process. The proposed research will identify alternative coating methods which improve material yield and reduce equipment capital requirements. In addition, it will demonstrate that spinel is a lower cost alternative to the LSM material. The demonstrated functionality of the APS/LSM system will be used as a metric to gauge the acceptability of the new materials