Enhanced thermal shock resistance of 8YSZ ceramic electrolytes through a 3D-printed architectural design

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Additive manufacturing of 8 mol% yttria-stabilized zirconia (8YSZ) electrolytes offers opportunities to improve cell performance through increased effective surface area. However, the intrinsic brittleness of 8YSZ ceramic electrolytes and its susceptibility to thermal stresses remain critical limitations. In this work, the potential of fabricating thermal-shock resistant complex-shaped electrolytes for solid oxide cell (SOC) applications using vat photopolymerization ceramic 3D printing is investigated. The material properties of 3D-printed electrolytes, including biaxial strength and fracture toughness, thermo-elastic properties as well as ionic conductivity, are systematically characterized. The thermomechanical behavior of planar and complex-shaped electrolytes is evaluated using water quenching thermal shock tests with a temperature difference of 600 °C. The higher thermal shock resistance of the complex-shaped electrolytes holding 90% higher surface area, compared to that of the planar counterparts, demonstrates the potential of additive manufacturing to provide higher functionality and improved thermo-mechanical reliability in SOC systems.