Powder coatings for solid oxide fuel cell interconnects

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Solid Oxide Fuel Cells (SOFCs) is very promising amongst other fuel cells technologies in terms of fuel flexibility, low emission and the ability to combine with other turbines. As one of the key components, researchers tried many ways to reduce the cost and enhance the compatibility of interconnects. A novel volume manufacture of chromium-rich metallic interconnects by powder metallurgy (powdered-metal, PM) processing has been successfully developed by Stackpole International. There is a need by SOFC builder to develop an industrial scale manufacturing method for the application of diffusion barrier coatings to the PM interconnects. The coatings must inhibit outward diffusion of chromium and provide high electrical conductivity at the SOFC operating temperature. Currently air-plasma spray (APS) methods are used to apply diffusion barrier coatings, but with low transfer efficiency and relatively high equipment investment. So there is a great need to develop an economical, high efficiency, quality consistent and environment-friendly way of applying the diffusion barrier coatings onto the interconnect substrate. At the University of Western Ontario, the powder technology and fluidization research group of Prof. Jingxu (Jesse) Zhu specializes in research and industrial scale-up of fine particle fluidization and powder coatings. With rich experiences in powder handling, the researchers are aiming at finding a novel way of using powder coatings directly onto the substrates. Stackpole International have the collaborative abilities to support the project from several perspectives, and if the project becomes successful, it will provide significant increase in value of manufactured product at SI Mississauga Powder Metallurgy Division and will increase employment opportunities for highly qualified personnel and supporting manufacturing employees. And the University of Western Ontario will be able to broaden the application area of fine powder technology and make contributions to real industrial uses.