Ultrathin Atomic Layer-Deposited CeO2 Overlayer for High-Performance Fuel Cell Electrodes

A Self-Assembled Multiphasic Thin Film as an Oxygen Electrode for Enhanced Durability in Reversible Solid Oxide Cells

The implementation of nanocomposite materials as electrode layers represents a potential turning point for next-generation of solid oxide cells in order to reduce the use of critical raw materials. However, the substitution of bulk electrode materials by thin films is still under debate especially due to the uncertainty about their performance and stability under operando conditions, which restricts their use in real applications. In this work, we propose a multiphase nanocomposite characterized by a highly disordered microstructure and high cationic intermixing as a result from thin-film self-assembly of a perovskite-based mixed ionic-electronic conductor (lanthanum strontium cobaltite) and a fluorite-based pure ionic conductor (samarium-doped ceria) as an oxygen electrode for reversible solid oxide cells. Electrochemical characterization shows remarkable oxygen reduction reaction (fuel cell mode) and oxygen evolution activity (electrolysis mode) in comparison with state-of-the-art bulk electrodes, combined with outstanding long-term stability at operational temperatures of 700 °C. The disordered nanostructure was implemented as a standalone oxygen electrode on commercial anode-supported cells, resulting in high electrical output in fuel cell and electrolysis mode for active layer thicknesses of only 200 nm (>95% decrease in critical raw materials with respect to conventional cathodes). The cell was operated for over 300 h in fuel cell mode displaying excellent stability. Our findings unlock the hidden potential of advanced thin-film technologies for obtaining high-performance disordered electrodes based on nanocomposite self-assembly combining long durability and minimized use of critical raw materials.

Atomic Layer Deposition of CeO2 Film with a Novel Heteroleptic Ce(III) Complex

In this paper, four heteroleptic Ce(III) complexes, including Ce(thd)3-phen (thd = 2,2,6,6-tetramethyl-3,5-heptanedione, phen = 1, 10-phenanthroline (1), Ce(thd)3-MEDA (MEDA = N-Methylethylenediamine (2), Ce(thd)3-MOMA (MOMA = N-(2-Methoxyethyl)methylamine (3), and Ce(thd)3-DMDE (DMDE = N,N″-dimethyl ethanol amine (4), were synthesized and characterized with 1H-NMR, elemental analysis, and X-ray single-crystal diffraction. The thermogravimetric analysis and vapor pressure results indicated that the complexing ability of a nitrogen-containing bidentate ligand with a cerium ion was stronger than that of a mixed oxygen-nitrogen-containing bidentate ligand. Complex 2 was selected as an ALD precursor to deposit a CeO2 film on a SiO2/Si (100) wafer. The self-limited deposition results demonstrated that complex 2 was a potential ALD precursor.

Thermally Stable Silver Cathode Covered by Samaria-Doped Ceria for Low-Temperature Solid Oxide Fuel Cells

Samaria-doped ceria (SDC) overlayers were deposited on Ag cathodes by sputtering. The SDC sputtering time was varied to investigate the properties of the Ag-SDC overlayer cathode-coated fuel cells depending on the thickness of the SDC overlayers. Among the fabricated fuel cells, Ag with a 10-nm-thick SDC overlayer (Ag-SDC10) cathode-coated fuel cell exhibited the highest peak power density of 6.587 mW/cm2 at 450 °C, showing higher performance than a pristine Pt-coated fuel cell. Moreover, electrochemical impedance spectroscopy revealed that the Ag-SDC10 cathode-coated fuel cell significantly mitigated polarization loss originating from enhanced oxygen reduction reaction kinetics compared to the pristine Ag-coated fuel cell.

Simultaneous Performance and Stability Enhancement in Intermediate Temperature Solid Oxide Fuel Cells by Powder-Atomic Layer Deposited LSCF@ZrO2 Cathodes

Employing porous structures is essential in high-performance electrochemical energy devices. However, obtaining uniform functional coatings on high-tortuosity structures can be challenging, even with specialized processes such as atomic layer deposition (ALD). Herein, a novel method for achieving a porous composite electrode for solid oxide fuel cells by coating La0.6 Sr0.4 Co0.2 Fe0.8 O3 -δ (LSCF) powders with ZrO2 using a powder ALD process is presented. Unlike conventional ALD, powder ALD can be used to fabricate extremely uniform coatings on porous electrodes with a thickness of tens of micrometers. The powder ALD ZrO2 coating is found to effectively suppress chemical degradation of the LSCF electrodes. The cell with the powder ALD coated cathode shows a 2.2 times higher maximum power density and 60% lower thermal degradation in activation resistance than the bare LSCF cathode cell at 700-750 °C. The result demonstrated in this study is expected to have significant implications for high-performance and durable electrodes in energy conversion/storage devices.

Nanocrystal Engineering of Thin-Film Yttria-Stabilized Zirconia Electrolytes for Low-Temperature Solid-Oxide Fuel Cells

To overcome significantly sluggish oxygen-ion conduction in the electrolytes of low-temperature solid-oxide fuel cells (SOFCs), numerous researchers have devoted considerable effort to fabricating the electrolytes as thin as possible. However, thickness is not the only factor that affects the electrolyte performance; roughness, grain size, and internal film stress also play a role. In this study, yttria-stabilized zirconia (YSZ) was deposited via a reactive sputtering process to fabricate high-performance thin-film electrolytes. Various sputtering chamber pressures (5, 10, and 15 mTorr) were investigated to improve the electrolytes. As a result, high surface area, large grain size, and residual tensile stress were successfully obtained by increasing the sputtering pressure. To clarify the correlation between the microstructure and electrolyte performance, a YSZ thin-film electrolyte was applied to anodized aluminum oxide-supported SOFCs composed of conventional electrode materials which are Ni and Pt as the anode and the cathode, respectively. The thin-film SOFC with YSZ deposited at 15 mTorr exhibited the lowest ohmic resistance and, consequently, the highest maximum power density (493 mW/cm2) at 500 °C whose performance is more than five times higher than that of the cell with YSZ deposited at 5 mTorr (94.1 mW/cm2). Despite the basic electrode materials, exceptionally high performance at low operating temperature was achieved via controlling the single fabrication condition for the electrolyte.

Improving the electrochemical energy conversion of solid oxide fuel cells through the interface effect in La0.6Sr0.4Co0.2Fe0.8O3-δ-BaTiO3-δ electrolyte

Herein, we present a heterostructure electrolyte with considerable potential for application in low-temperature solid oxide fuel cells (LT-SOFCs). Heterostructure electrolytes are advantageous because the multiphase interfaces in their heterostructures are superior for ion conduction than for bulk conduction. Most previous studies on heterostructure electrolytes explained the influence of interfacial parameters on ion conduction in terms of the space charge zones and lattice mismatch, neglecting the characterization of the interface. In this study, a series of heterostructure electrolytes comprising La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) and BaTiO_3-δ (BTO) with different composition ratios was developed. Further, the lattice mismatch due to thermal stress in this system was evaluated by thermal expansion and electron energy loss spectroscopy (EELS) analyses. Results indicated that 7LSCF-3BTO produced the narrowest interface and the most surface oxygen vacancies, suggesting that the stress generated by thermal expansion increased the density of the interface. The cell with the optimal 7LSCF-3BTO composition delivered a peak power density of 910mW cm^-2 and an open circuit voltage of 1.07 V at 550 °C. The heterojunction effect was studied to elucidate the prevention of short circuiting in the LSCF-BTO cell, considering the Femi level and barrier energy height. This study provides novel ideas for the design of electrolytes for LT-SOFCs from the interface perspective.

A Self-Crystallized Nanofibrous Ni-GDC Anode by Magnetron Sputtering for Low-Temperature Solid Oxide Fuel Cells

The optimum composition ratio of the anode cermet (Ni-GDC) for solid oxide fuel cells (SOFCs) varies because the electron-collecting mechanism is different depending on its applications. A Co-sputtering method facilitates ratio control with sputtering power adjustment. However, there is a practical issue with fabricating anode cermet with various ratios attributed to the large sputtering yield gap of the metal target, Ni, and the ceramic target, gadolinia-doped ceria (GDC). Therefore, in this study, a Gd-Ce metal alloy was applied instead of GDC to match the sputtering rate with that of Ni, which enables a wide ratio range achievement. A thin film of Gd-Ce oxidized after deposition and successfully transformed to crystallized GDC under a SOFC operation environment. X-ray diffraction (XRD) and high-resolution transmission electron microscopy (HRTEM) confirmed its crystallinity, and the film deposited with various power ratios was sputtered on the ScSZ electrolyte pellet to clarify the optimum Ni-GDC ratio for thin-film SOFCs. Last, the Ni-GDC was applied to anodized aluminum oxide (AAO)-supported SOFCs to maximize the performance. The performance change according to the thickness of Ni-GDC was identified, and the best performance among them was 638 mW/cm² at 500 °C.

Zirconia- and ceria-based electrolytes for fuel cell applications: critical advancements toward sustainable and clean energy production

Solid oxide fuel cells (SOFCs) are emerging as energy conversion devices for large-scale electrical power generation because of their high energy conversion efficiency, excellent ability to minimize air pollution, and high fuel flexibility. In this context, this critical review has focussed on the recent advancements in developing a suitable electrolyte for SOFCs which has been required for the commercialization of SOFC technology after emphasizing the literature from the prior studies. In particular, the significant developments in the field of solid oxide electrolytes for SOFCs, particularly zirconia- and ceria-based electrolytes, have been highlighted as important advancements toward the production of sustainable and clean energy. It has been reported that among various electrolyte materials, zirconia-based electrolytes have the potential to be utilized as the electrolyte in SOFC because of their high thermal stability, non-reducing nature, and high mechanical strength, along with acceptable oxygen ion conductivity. However, some studies have proved that the zirconia-based electrolytes are not suitable for low and intermediate-temperature working conditions because of their poor ionic conductivity to below 850 °C. On the other hand, ceria-based electrolytes are being investigated at a rapid pace as electrolytes for intermediate and low-temperature SOFCs due to their higher oxygen ion conductivity with good electrode compatibility, especially at lower temperatures than stabilized zirconia. In addition, the most emerging advancements in electrolyte materials have demonstrated that the intermediate temperature SOFCs as next-generation energy conversion technology have great potential for innumerable prospective applications.

Sol-Gel Combustion-Assisted Electrostatic Spray Deposition for Durable Solid Oxide Fuel Cell Cathodes

The chemical instability of perovskite oxides containing Sr is a critical issue for the long-term operation of solid oxide fuel cells. In this study, we demonstrate a remarkable improvement in the chemical and electrochemical stability of a heterostructured La_0.6Sr_0.4CoO_3-δ (LSC)-Ce_0.9Gd_0.1O_1.95 (GDC) electrode. Electrostatic spray deposition was employed to fabricate heterostructured nanoparticles in a single step with a coaxial nozzle supplying the LSC powders in the core nozzle and the GDC precursors in the shell nozzle. Moreover, the reducing fuel added to the GDC precursor solution induced the sol-gel combustion reaction in the droplet to form a uniform nanocrystalline GDC coating with high surface coverage. The high surface coverage of GDC on the LSC more significantly improved long-term stability compared with than of the bare LSC cathode at a constant current density of 1 A/cm² at 600°C for 100 h.

Nanoscale interface engineering for solid oxide fuel cells using atomic layer deposition

Atomic layer deposition (ALD), which is already actively used in the semiconductor industry, has been in the spotlight in various energy fields, such as batteries and fuel cells, given its unique ability to enable the nanoscale deposition of diverse materials with a variety of compositions onto complex 3D structures. In particular, with regard to ceramic fuel cells, ALD has attracted attention because it facilitates the manufacturing of thin and dense electrolytes. Furthermore, recently, electrode surfaces and electrode/electrolyte interface modification are arising as new research strategies to fabricate robust fuel cells. In this mini-review, we present a brief overview of ALD and recent studies that utilize ALD in ceramic fuel cells, such as manufacturing thin film electrolytes, stabilizing electrodes, functionalizing electrodes, and modifying the chemistry of electrode surfaces. We also propose research directions to expand the utility and functionality of the ALD techniques.

Catalyst overcoating engineering towards high-performance electrocatalysis

Clean and sustainable energy needs the development of advanced heterogeneous catalysts as they are of vital importance for electrochemical transformation reactions in renewable energy conversion and storage devices. Advances in nanoscience and material chemistry have afforded great opportunities for the design and optimization of nanostructured electrocatalysts with high efficiency and practical durability. In this review article, we specifically emphasize the synthetic methodologies for the versatile surface overcoating engineering reported to date for optimal electrocatalysts. We discuss the recent progress in the development of surface overcoating-derived electrocatalysts potentially applied in polymer electrolyte fuel cells and water electrolyzers by correlating catalyst intrinsic structures with electrocatalytic properties. Finally, we present the opportunities and perspectives of surface overcoating engineering for the design of advanced (electro)catalysts and their deep exploitation in a broad scope of applications.

Effectively Promoting Activity and Stability of a MnCo2O4-Based Cathode by In Situ Constructed Heterointerfaces for Solid Oxide Fuel Cells

The development of multiphase composite electrocatalysts plays a key role in achieving the efficient and durable operation of intermediate-temperature solid oxide fuel cells (IT-SOFCs). Herein, a self-assembled nanocomposite is developed as the oxygen reduction reaction (ORR) catalyst for IT-SOFCs through a coprecipitation method. The nanocomposite is composed of a doped (Mn_0.6Mg_0.4)_0.8Sc_0.2Co₂O₄ (MMSCO) spinel oxide (84 wt %), an orthorhombic perovskite phase (11.3 wt %, the spontaneous combination of PrO₂ additives and spinel), and a minor Sc₂O₃ phase (4.7 wt %). The surface of the (Mn_0.6Mg_0.4)_0.8Sc_0.2Co₂O₄ phase is activated by the self-assembled nanocoating with many heterogeneous interfaces. Thence, the ORR kinetics is obviously accelerated and an area-specific resistance (ASR) of ∼0.11 Ω cm² is obtained at 750 °C. Moreover, a single cell with the cathode shows a peak power density (PPD) of 1144.1 mW cm^-2 at 750 °C, much higher than that of the cell with the MnCo₂O₄ cathode (456.2 mW cm^-2). An enhanced stability of ∼120 h (0.8 A cm^-2, 750 °C) is also achieved, related to the reduced thermal expansion coefficient (13.9 × 10^-6 K^-1). The improvement in ORR kinetics and stability can be attributed to the refinement of grains, the formation of heterointerfaces, and the enhancement of mechanical compatibility.

Deconvolution of Water-Splitting on the Triple-Conducting Ruddlesden-Popper-Phase Anode for Protonic Ceramic Electrolysis Cells

Triple-conducting materials have been proved to improve the performance of popular protonic ceramic electrolysis cells. However, partially because of the complexity of the water-splitting reaction involving three charge carriers, that is, oxygen (O^2-), proton (H⁺), and electron (e^-), the triple-conducting reaction mechanism was not clear, and the reaction conducting pathways have seldom been addressed. In this study, the triple-conducting Ruddlesden-Popper phase Pr_1.75Ba_0.25NiO_4+δ as an anode on the BaCe_0.7Zr_0.1Y_0.1Yb_0.1O_3-δ electrolyte was fabricated and its electroresponses were characterized by electrochemical impedance spectroscopy with various atmospheres and temperatures. The impedance spectra are deconvoluted by means of the distribution of the relaxation time method. The surface exchange rate and chemical diffusivity of H⁺ and O^2- are characterized by electrical conductivity relaxation. The physical locations of electrochemical processes are also identified by atomic layer deposition with a surface inhibitor. A microkinetics model is proposed toward conductivities, triple-conducting pathways, reactant dependency, surface exchange and bulk diffusion capabilities, and other relevant properties. Finally, the rate-limiting steps and suggestions for further improvement of electrode performance are presented.