Fabrication of dense YSZ electrolyte membranes by a modified dry-pressing using nanocrystalline powders

A simple and cost-effective method for synthesizing yttria-stabilized zirconia (YSZ) electrolyte membranes is described that is based on a modified dry-pressing process using nanocrystalline powders. The thickness of the YSZ electrolyte membranes was easily controlled by controlling the mass of nanocrystalline YSZ powders. Good adhesion of the dense electrolyte membranes to the anode substrates without cracking or delamination could be readily obtained. The studied single cell possessed much higher open circuit voltage (OCV) and higher output performance than a cell whose electrolyte thick film was made from a traditional dry-pressing method using commercially microcrystalline powders. The good performance in this study was attributable to the successful fabrication of the electrolyte membrane by the uniquely modified dry-pressing process using loose nanocrystalline YSZ powders. The implementation of the modified dry-pressing process using nanocrystalline YSZ powders to fabricate electrolyte membranes exhibits a significant potential to greatly reduce the fabrication cost of solid oxide fuel cells (SOFCs).