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With these improvements, interconnects can be made that function in intermediate temperature SOFCs, although several additional improvements may still require attention to allow the construction of commercially viable products: • Further improvement in contact resistance, especially after long exposure and thermal cycling • Further improvements in corrosion resistance, especially after long exposure and thermal cycling • Improved performance and mechanical stability of the coatings • Low-cost manufacturing methods for materials, shapes, and coatings • Improved creep strength to increase design flexibility for cells SOFC anodes are fabricated from composite powdered mixtures of electrolyte materials (YSZ, GDC, or SDC) and nickel oxide. The nickel oxide is subsequently reduced to nickel metal prior to operation. The NiO/YSZ anode material is suited for applications with YSZ material, whereas NiO/SDC and NiO/GDC anode materials are best used with ceria-based electrolyte materials. Typical anode materials have nickel content of approximately 40 volume percent after reduction of the nickel oxide to nickel. Depending upon the application, powders have surface areas of 15 to 20 m2/g for screen-printing and 5 to 10 m2/g for tape casting. 7.1.5 SealMaterials The challenges of sealing the oxidant from fuel in planar SOFC stacks is significant, hence a sub-section is devoted to potential seal materials here. The function of SOFC seals includes: • Prevent mixing of fuel and oxidant • In some configurations, prevent mixing of reactants with the ambient environment • In some configurations, provide mechanical bonding of components • In some designs, provide electrical insulation between stack components Seal materials must be chemically and physically stable at operating conditions. In some applications (e.g. in on-road vehicles), the seal must also be able to withstand acceleration forces associated with vibration and shock. Finally, seal materials must be low in cost and amenable to low-cost stack manufacturing methods. These requirements are tough to meet simultaneously. For example, the chemical stability of a material may be acceptable under either oxidizing or reducing environments. However, mechanistic characterizations have shown that when relatively thin pieces of material are exposed to both atmospheres, rapid deterioration occurs.(29). Seal designs are highly specific to particular cell and stack designs and, consequently, seal designs are often proprietary. Some tubular and monolithic designs require no seals at all. Planar designs typically require multiple seals per repeat unit, and even in planar designs the length of the seals can vary by two or three orders of magnitude for a given area cell depending on design. A number of possible seal types is shown in Figure 7-6 for a rectangular planar cell with metal interconnects. 7-9PDF Image | Fuel Cell Handbook (Seventh Edition)
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