Solid Oxide Fuel Cell Interconnects via High-Pressure Powder Metallurgy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing interconnects for solid oxide fuel cells, particularly those using chrome base alloys, face challenges in achieving high density and cost-effectiveness due to the need for multiple pressing and sintering processes, and the materials used, such as ceramics, are expensive and fragile.
Innovation Solution
A powder metallurgy method involving a CNC hydraulic pressing machine with pressures over 8 mt/cm² to achieve a green interconnect density of at least 90% theoretical density, followed by sintering and a ceramic protecting process to form a high-quality chrome base alloy interconnect with reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional ceramic materials are used for interconnects, then high temperature resistance is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent replaces expensive, fragile ceramic interconnects with metal interconnects that are cheaper, easier to manufacture, and sufficiently durable for the application. This substitution directly addresses the contradiction by using a material that is both cost-effective and manufacturable while maintaining the required high temperature resistance through proper material selection and protective coatings.
Solution Approach 2:
The patent changes the material parameter from ceramic to metal (specifically stainless steel or nickel-based alloys), which fundamentally alters the manufacturing process and properties. This parameter change enables simpler manufacturing methods such as conventional metal forming, welding, and machining, thereby reducing manufacturing complexity while maintaining high temperature resistance through appropriate alloy composition and surface treatments.
2Manufacturing precision
If multiple pressing and sintering processes are used, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by using high-power pressure (at least 8 mt/cm²) in the pressing process to achieve high green density (at least 90% theoretical density) before sintering. This preliminary densification reduces the complexity and number of subsequent processing steps needed, thereby improving productivity while maintaining manufacturing precision through controlled high-pressure forming.
3Manufacturing precision
If high pressure pressing is applied, then green interconnect density is improved, but equipment complexity increases
Solution Approach 1:
The patent employs hydraulic pressing equipment to generate and control the high pressure (at least 8 mt/cm²) required for achieving high green density. By using hydraulic systems, the complex high-pressure generation is achieved through fluid pressure transmission, which simplifies the overall equipment design compared to mechanical high-pressure systems while enabling precise density control through pressure regulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of high-density, cost-effective chrome base alloy interconnects with improved mechanical properties and thermal stability, reducing production costs and enhancing the efficiency of solid oxide fuel cells.
Implementation Method 1
a pressing process is performed on the mixture by a computer numerical control (CNC) hydraulic pressing machine with a pressure equal to or over 8 metric ton/cm2
Implementation Method 2
a pressing process is performed on the mixture with a pressure equal to or over 8 mt/cm2 to form a green interconnect with a density equal to or over 90% of the theoretical density
Implementation Method 3
a sintering process is performed on the green interconnect to form an interconnect body
Data Source
AI summary
A method for forming an interconnect of a solid oxide fuel cell includes the following steps. First of all, a powder mixture substantially including equal to or more than 90 wt % chromium powder, with the balance being iron powder and inevitable impurities, is provided. Then the powder mixture is pressurized by a pressing process with a pressure equal to or over 8 mt/cm2 to form a green interconnect with a density being equal to or over 90% of the theoretical density. Next the green interconnect is sintered by a sintering process to form an interconnect body. Finally, a protection process is performed on at least one surface of the interconnect body to form an interconnect.