Cofiring of Thin Zirconia Films During SOFC Manufacturing

High‐performance solid oxide fuel cells require a thin and gas‐tight electrolyte membrane that must be coated on a porous and relatively rough support. A pretreatment of the delivered submicronmeter electrolyte powder of 8 mol%‐yttria‐stabilized zirconia (8YSZ) yielded a reduced sintering mismatch between the anode substrate made from NiO/8YSZ and the electrolyte coating. Furthermore, it also enhanced the powder packing inside the green film. Constrained sintering usually leads to inadequate film density and an unfavorable pore deformation and orientation. It was demonstrated that these limitations can be resolved by using a coshrinking substrate in a planar cell design. Relative densities of >97% were achieved, which are higher than those for free‐standing layers. Additionally, the camber behavior was investigated in dependence of the temperature program with and without gravity effects, giving an overall suggestion for the cofiring parameters of the electrolyte.