Microstructure optimization of nickel/gadolinium-doped ceria anodes as key to significantly increasing power density of metal-supported solid oxide fuel cells

Metal-supported solid oxide fuel cells (MSCs) are promising candidates for mobile power generators like range extenders for battery electric vehicles due to their improved thermal conductivity and ruggedness. The limited space available in such vehicles heightens the need to achieve high power densities. In the present study, a significant increase in cell performance of the MSC concept of Plansee SE was demonstrated by means of systematic microstructure optimization of the complete cell architecture based on improved processing. Thickness and roughness of multi-layered Ni/GDC anode play a particularly important role in improving cell performance. After several optimization steps, a notable increase of current density from 1.29 A/cm2 to 1.79 A/cm2 at 700 °C and 0.7 V (+38%) was achieved. Additionally, lowering the anode roughness enables clear reduction of electrolyte thickness down to 2 μm, a starting point for the further enhancement of cell performance