Additive Manufacturing of Single-Layer Protonic Ceramic Fuel Cells

Single-layer proton conducting ceramic fuel cells (PCFCs) were fabricated through a hybrid of extrusion-based 3D printing utilizing BaZr0.4Ce0.4Y0.1Yb0.1O3-δ (BZCYYb) as an ionic conductor, and BaCo0.4Fe0.4Zr0.1Y0.1O3-δ (BCFZY) as the electrode material. The rheological properties of the printable pastes were investigated in detail. The 3D printed single-layer cell produced a maximum power density of 283 mW/cm2 at 550oC. The performance was mainly limited due to limited surface area on both sides of the cell. The performance improved by 17% (331 mW/cm2) when porous layers were added on both sides of the cell. In addition, cells with traditional 3-layer structure were fabricated using NiO-BZCYYb as anode, BZCYYb as electrolyte, and BCFZY-BZCYYb as cathode. The cell produced a maximum power density of 426 mW/cm2 at 650OC. The performance improved by 120% (938 mW/cm2) when a composite of BZCYYb and a eutectic mixture of Li2CO3, Na2CO3 and K2CO3 was used as electrolyte.