Plasma sprayed ceramic-metal fuel electrode
View Patent ↗A plasma sprayed ceramic-metal fuel electrode is provided. The fuel electrode has particular application in connection with a solid oxide fuel cell used within a power generation system. The fuel cell advantageously comprises an air electrode, an electrolyte formed on at least a portion of the air electrode, a plasma sprayed ceramic-metal fuel electrode formed on at least a portion of the electrolyte, and an interconnect layer to connect adjacent cells in a generator.
1. A tubular solid oxide fuel cell, comprising:
an air electrode;
an electrolyte formed on at least a portion of the air electrode; and
a ceramic-metal fuel electrode comprising nickel and zirconia and having a microstructure characterized by accumulated molten particle splats formed on at least a portion of the electrolyte,
wherein a nickel graphite powder is used to obtain at least a portion of the nickel.
2. The fuel cell of claim 1 , wherein the nickel graphite powder comprises at least 60% nickel and at least 15% graphite.
3. The fuel cell of claim 2 , wherein the nickel graphite powder comprises at least 70% nickel and at least 20% graphite.
4. A tubular solid oxide fuel cell, comprising:
an air electrode;
an electrolyte formed on at least a portion of the air electrode; and
a ceramic-metal fuel electrode comprising nickel and zirconia and having a microstructure characterized by accumulated molten particle splats formed on at least a portion of the electrolyte,
wherein a yttria stabilized zirconia powder is used to obtain at least a portion of the zirconia.
5. The fuel cell of claim 4 , wherein the yttria stabilized zirconia powder comprises at least 7 mole percent of yttria.
6. The fuel cell of claim 5 , wherein the yttria stabilized zirconia powder comprises at least 8 mole percent of yttria.