Fuel cell interconnect with reduced voltage degradation over time

1. A method of making an interconnect for a solid oxide fuel cell stack, comprising: providing a chromium alloy interconnect; forming a contact layer on only a portion of top surfaces of ribs on a fuel side of the interconnect, wherein the contact layer comprises a material selected from the group of nickel, nickel oxide, platinum, rhodium, palladium, ruthenium, copper, iron, cobalt, silver, gold, and tungsten; and providing a nickel mesh in contact with a fuel side of the interconnect, wherein formation of a chromium oxide layer is reduced or avoided in locations between the nickel mesh and the fuel side of the interconnect by the contact layer and wherein the contact layer comprises gaps exposing mesh weld points on the fuel side of the interconnect.

2. The method of claim 1 , wherein the fuel side of the interconnect comprises a Cr—Ni alloy or a Cr—Fe—Ni alloy under the nickel mesh.

3. The method of claim 1 , wherein the formation of the chromium oxide layer is further reduced or avoided by at least one of increasing compression pressure between the nickel mesh and the interconnect, providing undiffused Fe in the interconnect under the nickel mesh, reducing surface contamination between the interconnect and the nickel mesh, attaching the nickel mesh to the interconnect, and adding nickel to the interconnect alloy.

4. The method of claim 1 , wherein the formation of the chromium oxide layer is further reduced or avoided by increasing the compression pressure between the nickel mesh and the interconnect by generating a pressure field or gradient on the nickel mesh.

5. The method of claim 4 , wherein the ribs in a middle of the interconnect have a greater height than the ribs in a periphery of the interconnect to generate the pressure field or gradient on the mesh in a solid oxide fuel cell stack.

6. The method of claim 3 , wherein providing the undiffused Fe in the interconnect under the nickel mesh comprises one of:

pressing a chromium and iron containing powder to form the interconnect followed by partially sintering the interconnect at a lower temperature or a shorter duration than that required for fully alloying the iron and chromium powder particles; and

pressing a mixture of a chromium powder having a first average particle size and iron powder having a second particle size larger than the first particle size to form the interconnect followed by sintering the interconnect.

7. The method of claim 1 , wherein:

the formation of the chromium oxide layer is further reduced or avoided by adding nickel to the interconnect alloy; and

the nickel fully or partially substitutes iron in the fuel side of the interconnect.

8. The method of claim 7 , wherein the nickel fully or partially substitutes iron only in the fuel side of the interconnect by providing nickel powder having a different average particle size than chromium powder in a mold cavity.

9. The method of claim 7 , wherein the nickel fully or partially substitutes iron only in the fuel side of the interconnect by:

providing first metallic powder particles comprising Cr and Fe in a mold cavity;

providing second powder particles comprising nickel in the mold cavity; and

compacting the first and second powder particles to form the interconnect.

10. The method of claim 9 , wherein:

the first or the second powder particles are provided to the mold first and the other ones of the first or the second powder particles are electrostatically attracted to a bottom surface of a punch used to compact the powder particles; and

the punch presses the first powder and the second powder to compact the first and the second power particles.

11. The method of claim 1 , wherein the contact layer is formed by screen printing a nickel or nickel oxide containing ink.

12. The method of claim 11 , wherein the contact layer does not coat an entire top surface of all of the ribs on the fuel side of the interconnect.

13. The method of claim 11 , wherein:

the contact layer provides conductive pathways through the chromium oxide layer; and

the conductive pathways are provided by nickel diffusion from the contact layer through the chromium oxide layer.

14. The method of claim 11 , wherein the contact layer increases an area of contact between the mesh and the ribs on the fuel side of the interconnect.

15. The method of claim 11 , wherein the contact layer blocks diffusion of impurities from the mesh into the chromium oxide layer.