Achieving high mechanical-strength CH₄-based SOFCs by low-temperature sintering (1100 °C)

Despite much progress achieved in the past decades in the process of advancing the low-temperature sintering technologies for Solid oxide fuel cells (SOFCs), such as via the structure design of the electrode materials, the practical application of low-temperature sintered SOFCs (with disqualified mechanical strength) remains challenging. In this work, first, we demonstrate that the appropriate amount of CuO as sintering aids can successfully reduce the co-firing temperature of conventional micron size NiO-YSZ (yttrium-stabilized zirconia (Y₂O₃)_0.08–(ZrO₂)_0.92) anode from about 1400 °C to only 1100 °C. Second, the quantitative structure-activity relationship among the mechanical strength (low-temperature sintering ability) of anode cermets with the inclusion of CuO contents and the densification of YSZ electrolyte was synthetically evaluated, and the optimal Cu–NiO-YSZ anode composition demonstrates almost the equal mechanical strength when compared with the traditional NiO-YSZ anode (sintering at 1400 °C). At last, by comprehensive assessment, 8%Cu–52NiO-40YSZ (8%CuO–NiO-YSZ) shows excellent low-temperature sintering ability, high mechanical strength, optimal power output, and anti-carbon deposition when using as hydrocarbon-based anode for SOFCs.