Solid oxide fuel cell having metal support with a compliant porous nickel layer

1. A fuel cell comprising:

a cell including a solid oxide electrolyte between electrodes, the cell having a first coefficient of thermal expansion;

a metallic support in electrical connection with one of the electrodes, the metallic support including a metal substrate and a compliant porous nickel layer that is bonded to the metal substrate between the cell and the metal substrate, the metal substrate having a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell, wherein the metal substrate has a first stiffness and the compliant porous nickel layer has a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate; and

a bonding layer between the cell and the compliant porous nickel layer, the bonding layer being interfacially bonded with the compliant porous nickel layer and the cell.

2. The fuel cell as recited in claim 1 , wherein the compliant porous nickel layer is a wire mesh.

3. The fuel cell as recited in claim 1 , wherein the metal substrate comprises stainless steel.

4. The fuel cell as recited in claim 1 , wherein the compliant porous nickel layer is electrically connected with a cathode of the electrodes.

5. A fuel cell comprising:

a cell including a solid oxide electrolyte between electrodes, the cell having a first coefficient of thermal expansion; and

a metallic support in electrical connection with one of the electrodes, the metallic support including a metal substrate and a compliant porous nickel layer that is bonded to the metal substrate between the cell and the metal substrate, the metal substrate having a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell, wherein the metal substrate has a first stiffness and the compliant porous nickel layer has a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate, wherein the metal substrate has a nominal composition comprising about 22 wt % chromium, about 14 wt % tungsten, about 2 wt % molybdenum, about 0.5 wt % manganese, about 0.4 wt % silicon, about 0.3 wt % aluminum, and a balance of nickel.

6. The fuel cell as recited in claim 1 , wherein the metal substrate is a solid plate having reactant gas channels.

7. The fuel cell as recited in claim 1 , wherein the metal substrate is a corrugated sheet.

8. The fuel cell as recited in claim 1 , wherein the metal substrate is a planar separator plate.

9. A method for processing a fuel cell, comprising:

providing a cell having a solid oxide electrolyte between electrodes, the cell having a first coefficient of thermal expansion;

bonding a compliant porous nickel layer to a metal substrate to form a metallic support such that the compliant porous nickel layer is between the cell and the metal substrate, with a bonding layer between the cell and the compliant porous nickel layer, the bonding layer being interfacially bonded with the compliant porous nickel layer and the cell, the metal substrate having a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell; and

establishing the metal substrate to have a first stiffness and the compliant porous nickel layer to have a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate.

10. The method as recited in claim 9 , including bonding the compliant porous nickel layer to the metal substrate using at least one of diffusion bonding or welding.

11. The method as recited in claim 9 , including selecting the metal substrate from a group consisting of a solid plate having reactant gas channels, a corrugated sheet, and a solid, planar separator plate.

12. The method as recited in claim 9 , including selecting the compliant porous nickel layer to be a wire mesh to thereby provide the second stiffness that is less than the first stiffness.

13. A method for processing a fuel cell, comprising:

providing a cell having a solid oxide electrolyte between electrodes, the cell having a first coefficient of thermal expansion;

bonding a compliant porous nickel layer to a metal substrate to form a metallic support such that the compliant porous nickel layer is between the cell and the metal substrate, the metal substrate having a second coefficient of thermal expansion that nominally matches the first coefficient of thermal expansion of the cell;

establishing the metal substrate to have a first stiffness and the compliant porous nickel layer to have a second stiffness that is less than the first stiffness such that the compliant porous nickel layer can thermally expand and contract with the metal substrate; and

selecting the metal substrate to include a composition comprising about 22 wt % chromium, about 14 wt % tungsten, about 2 wt % molybdenum, about 0.5 wt % manganese, about 0.4 wt % silicon, about 0.3 wt % aluminum, and a balance of nickel.

14. The fuel cell as recited in claim 1 , wherein the porous nickel layer is diffusion bonded to the metal substrate.

15. The fuel cell as recited in claim 1 , wherein the bonding layer is a distinct layer from the cell.

16. The fuel cell as recited in claim 15 , wherein the bonding layer is a solid oxide.

17. The fuel cell as recited in claim 1 , wherein the bonding layer is planar.