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1 0.9 0.8 0.7 0.6 0.5 1984 (10 Atm) 1976 (10 Atm) 1984 (1 Atm) 2002 (1 1967 (1 Atm) 0 50 100 150 200 250 300 350 Current Density, mA/cm2 Figure 6-3 Progress in the Generic Performance of MCFCs on Reformate Gas and Air (12, 13) The conventional process to fabricate electrolyte structures until about 1980 involved hot pressing (about 5,000 psi) mixtures of LiAlO2 and alkali carbonates (typically >50 vol percent in liquid state) at temperatures slightly below the melting point of the carbonate salts (e.g., 490°C for electrolyte containing 62 mol Li2CO3-38 mol K2CO3). These electrolyte structures (also called "electrolyte tiles") were relatively thick (1 to 2 mm) and difficult to produce in large sizes22 because large tooling and presses were required. The electrolyte structures produced by hot pressing are often characterized by 1) void spaces (<5 porosity), 2) poor uniformity of microstructure, 3) generally poor mechanical strength, and 4) high iR drop. To overcome these shortcomings of hot pressed electrolyte structures, alternative processes such as tape casting (7) and electrophoretic deposition (14) for fabricating thin electrolyte structures were developed. The greatest success to date with an alternative process has been reported with tape casting, which is a common processing technique used by the ceramics industry. This process involves dispersing the ceramic powder in a solvent23 that contains dissolved binders (usually an organic compound), plasticizers, and additives to yield the proper slip rheology. The slip is cast over a moving smooth substrate, and the desired thickness is established with a doctor blade device. After drying the slip, the "green" structure is assembled into the fuel cell where the organic binder is removed by thermal decomposition, and the absorption of alkali carbonate into the ceramic structure occurs during cell startup. 22. The largest electrolyte tile produced by hot pressing was about 1.5 m2 in area (7). 23. An organic solvent is used because LiAlO2 in the slip reacts with H2O. 6-6 Cell Voltage, VPDF Image | Fuel Cell Handbook (Seventh Edition)
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