Thermal Spraying Powder Pore Design for Uniform SOFC Electrodes
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Solution Overview
Problem
The challenge in forming fuel electrodes for solid oxide fuel cells (SOFC) and solid oxide electrolysis cells (SOEC) lies in uniformly dispersing ceramic and metal particles, which are required to reduce interface resistance and enhance the efficiency of these components.
Innovation Solution
A powder for thermal spraying is developed, comprising composite particles with specific pore diameter distributions and compositions, including ceramic and transition metal compound particles, to enhance uniformity and conductivity in the thermal-sprayed coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermal spraying powder is used to form fuel electrodes, then the coating can be formed, but the uniformity of components (ceramic particles, metal particles, and voids) in the thermal-sprayed coating is insufficient
Solution Approach 1:
The patent changes the pore diameter distribution parameter of the thermal spraying powder to a specific range (peak at 0.15-1 μm) to achieve uniform dispersion of ceramic particles, metal particles, and voids in the coating, thereby improving manufacturing precision and reducing interface resistance
Solution Approach 2:
The patent uses composite particles comprising both ceramic particles (ion conductive) and transition metal compound particles (electrically conductive) with controlled pore distribution, creating a multi-functional material that simultaneously achieves uniform coating formation and reduced interface resistance
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. This powder for thermal spraying has a peak within a range equal to or more than 0.15 µm and not more than 1 µm, on a log differential pore volume distribution for a pore diameter being equal to or less than 1 µm obtained by a mercury penetration method