Fabrication and microstructural characterization of additively manufactured metal supports for solid oxide fuel cells

Porous 430L stainless steel metal supports fabricated by direct metal laser sintering (DMLS) with various designed pore sizes were evaluated for solid oxide fuel cell (SOFC) applications. This study reports the metal support properties related to pore size and surface roughness that are critical for defect-free ceramic deposition. The supports were systematically characterized in terms of pore size fidelity and printability, surface pore distribution and roughness, and bridging layer deposition and adhesion relevant to SOFC fabrication and operation. Challenges associated with conventional pore former usage and pore size control were mitigated by designing and printing fine and straight-through pores, while overall porosity was custom-designed and optimized within the printability limit of the DMLS process. Pore size and surface pore distribution were quantified using scanning electron microscopy (SEM) micrographs and image processing techniques. Surface roughness was evaluated using an optical profilometer on bare, polished, gadolinium-doped ceria-coated, and yttria-stabilized zirconia-coated samples. The observed adhesion of the ceramic layers and the improved surface smoothness indicated good compatibility between the additively manufactured metal supports and ceramic coatings, supporting their potential for SOFC applications.