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better corrosion resistance to mitigate acidic cathode dissolution. However, it has lower wettability and greater temperature sensitivity. Additives are being investigated to minimize the temperature sensitivity of Li/Na. The electrolyte has a low vapor pressure at operating temperature, and may slowly evaporate. Stack testing has shown that the electrolyte vapor loss is significantly slower than expected. The evaporation loss is projected to have minimal impact on stack life. Electrolyte Structure: Ohmic losses contribute about a 65 mV loss at the beginning of life, and may increase to as much as 145 mV by 40,000 hours (16). The majority of the voltage loss is in the electrolyte and the cathode components. The electrolyte offers the highest potential for reduction because 70 percent of the total cell ohmic loss occurs there. FCE investigated increasing the porosity of the electrolyte 5 percent to reduce the matrix resistance by 15 percent, and change the melt to Li/Na from Li/K to reduce the matrix resistivity by 40 percent. Work is continuing on the interaction of the electrolyte with the cathode components. At the present time, an electrolyte loss of 25 percent of the initial inventory can be projected with a low surface area cathode current collector and with the proper selection of material. Another area for electrolyte improvement is the ability to prevent gas crossover from one electrode to the other. FCE produced an improved matrix fabrication process providing low temperature binder burnout. FCE reported in 1997 that it had developed a high performance rugged matrix that increases the gas sealing efficiency by approximately a factor of ten better than the design goal (43). Electrolyte Migration: There is a tendency for the electrolyte to migrate from the positive end of the stack to the negative end of the stack. This may cause the end cells to lose performance compared to the central cells. The electrolyte loss is through the gasket used to couple the external manifolds to the cell stack. The standard gasket material is porous and provides a conduit for electrolyte transfer. A new gasket design incorporating electrolyte flow barriers inside the gasket (US Patent 5,110,692) plus end cell inventory capability offers the potential for reaching 40,000 hours, if only this mode of failure is considered. Stacks with internal manifolding do not require a gasket, and may not experience this problem (44). Bipolar Plate: The present bipolar plate consists of a separator, current collectors, and the wet seal. The separator and current collector is Ni-coated 310S/316L and the wet seal is formed by aluminization of the metal. The plate is exposed to the anode environment of one side and the cathode environment on the other. Low oxygen partial pressure on the anode side of the bipolar plate prevents the formation of a protective oxide coating. After reaction with the thin, creeping electrolyte, heat-resistant alloys form a multi-layered corrosion scale. This condition may be accelerated by carbonization, higher temperature, and higher moisture gas environment. On the cathode side, contact electrical resistance increases as an oxide scale builds up. Electrolyte loss due to corrosion and electrolyte creep also contributes to power decay. Single alloy bipolar current collector materials that function well in both anode and cathode environments need to be developed. Although such development has been attempted, high cost and high ohmic resistance prevent it from being successful. Presently, stainless steels, particularly austenitic stainless steels, are the primary construction materials. More expensive nickel-based alloys resist corrosion as well as or only slightly better than austenitic stainless steels. A thermodynamically 6-12PDF Image | Fuel Cell Handbook (Seventh Edition)
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