Composite Thermal Spraying Powder for Uniform SOFC Electrodes
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Solution Overview
Problem
Existing fuel electrodes in solid oxide fuel cells (SOFC) and solid oxide electrolysis cells (SOEC) face challenges in uniformly dispersing ceramic and metal particles, leading to non-uniform thermal-sprayed coatings which affect the efficiency and conductivity of these components.
Innovation Solution
A thermal spraying powder comprising composite particles with ceramic and transition metal compound particles, designed to enhance uniformity and electrical conductivity, with specific granule strength, median diameter, and reduction process conditions to optimize electrode formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder mixtures are used for thermal spraying, then the coating can be formed, but the uniformity of components in the thermal-sprayed coating deteriorates
Solution Approach 1:
The invention segments the powder into composite particles containing both ceramic and metal phases within single particles. This segmentation ensures that each particle carries a fixed ratio of components, preventing segregation during storage and spraying, thereby achieving uniform component distribution in the thermal-sprayed coating.
Solution Approach 2:
The invention merges ceramic particles and metal particles into single composite particles. By combining multiple materials into one particle structure, the invention eliminates the problem of component separation that occurs with conventional mixtures, ensuring consistent composition throughout the coating.
2Adaptability or versatility
If ceramic particles and metal particles are mixed for fuel electrode, then both ion conductive property and electrical conductivity can be achieved, but the uniformity of dispersion deteriorates
Solution Approach 1:
The invention creates composite particles that integrate both ceramic materials (providing ion conductivity) and metal materials (providing electrical conductivity) within a single particle structure. This composite approach maintains both conductive properties while ensuring uniform dispersion, as the fixed internal structure prevents particle aggregation and segregation.
3Reliability
If particle mixture with specific mass ratio is used, then interface resistance can be reduced, but coating uniformity deteriorates due to particle segregation
Solution Approach 1:
The invention segments the multi-component system into individual composite particles, each containing the optimal ratio of ceramic to metal phases. This segmentation prevents the segregation that would otherwise occur with conventional mixtures, ensuring that the interface resistance benefits are maintained uniformly throughout the coating.
Data Source
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AI summary
Provided is a technique for enhancing a uniformity of components in a thermal-sprayed coating. The herein disclosed powder for thermal spraying is a powder for thermal spraying that is used to form an electrode of a solid oxide fuel cell or a solid oxide electrolysis cell. Regarding this powder for thermal spraying, a granule strength is equal to or more than 25 MPa.