Forming an impermeable sintered ceramic electrolyte layer on a metallic foil substrate for solid oxide fuel cell

1. A method of forming an impermeable sintered electrolyte ceramic layer of a solid oxide fuel cell, said method comprising the steps of:

depositing a ceramic powder onto a stainless steel foil substrate using electrophoretic deposition to form a deposited ceramic powder layer;

isostatically pressing said deposited ceramic layer to form a compressed ceramic powder layer; and

heating said compressed ceramic powder layer to a temperature of less than 1100° C. to sinter said compressed ceramic powder to form said sintered ceramic layer upon said substrate.

2. A method as claimed in claim 1 , wherein said substrate is ferritic stainless steel.

3. A method as claimed in claim 2 , wherein said substrate is a ferritic stainless steel having European designation 1.4509.

4. A method as claimed in claim 1 , wherein said step of heating heats said compressed ceramic powder layer to a temperature of less than 1000° C.

5. A method as claimed in claim 1 , wherein said step of heating takes place in one of an inert atmosphere, and a controlled oxygen partial pressure atmosphere.

6. A method as claimed in claim 5 , wherein said step of heating takes place in an Argon gas atmosphere, or a controlled oxygen partial pressure atmosphere.

7. A method as claimed in claim 1 , wherein said step of isostatically pressing applies a pressure of between 100 and 500 MPa.

8. A method as claimed in claim 1 , wherein said step of isostatically pressing uses a wet-bag isostatic press.

9. A method as claimed in claim 1 , wherein said sintered ceramic layer is an electrolyte layer within said solid oxide fuel cell.

10. A method as claimed in claim 1 , wherein said sintered ceramic layer is a CGO electrolyte layer.

11. A method as claimed in claim 10 , wherein said sintered layer is a Ce 0.9 Gd 0.1 O 1.95 layer.

12. A method as claimed in claim 1 , wherein said sintered ceramic layer and said substrate have a substantially equal coefficient of thermal expansion.

13. A solid oxide fuel cell including an impermeable sintered ceramic electrolyte layer formed in accordance with a method of claim 1 .

14. A method as claimed in claim 1 , wherein ceramic powder is substantially free from metal powder.

15. A method as claimed in claim 1 , wherein said ceramic powder is substantially free from organic binders or plasticizers.

16. A method as claimed in claim 1 , wherein said stainless steel foil substrate is a perforated stainless steel foil providing support for said sintered ceramic layer whilst allowing gas to flow through said stainless steel foil to said sintered ceramic layer.

17. A method as claimed in claim 1 , which utilises a porous intermediate ceramic electrode layer.

18. A method as claimed in claim 17 wherein said step of depositing includes depositing said ceramic electrolyte powder onto said porous intermediate ceramic electrode layer on said stainless steel foil substrate together with an overlapping region onto said stainless steel foil substrate.

19. A method as claimed in claim 17 , wherein said porous intermediate ceramic electrode layer is a ceramic anode layer.

20. A method as claimed in claim 19 , wherein said porous intermediate ceramic anode layer is formed of NiO/CGO powder.

21. A method a claimed in claim 19 , wherein said ceramic anode layer is sintered in a reducing atmosphere at below 1000° C.

22. A method as claimed in claim 1 , wherein a porous intermediate ceramic electrode layer is formed on said sintered ceramic layer.

23. A method a claimed in claim 22 , wherein said ceramic electrode layer is fired at between 700 and 800° C.

24. A method as claimed in claim 22 , wherein said porous intermediate ceramic electrode layer is a ceramic cathode layer.

25. A method as claimed in claim 24 , wherein said ceramic cathode layer is formed of Gd 1−x Sr x CoO 3 /CGO powder.