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SOFC Manufacturing Development at GE Global
Research Matt Alinger GE Global Research Niskayuna, NY
SOFCSOFC
13th Annual SECA Workshop Pittsburgh, PA July 24-25, 2012
2 SECA Annual Workshop
July 2012
GE Unveils Advanced-Manufacturing Battery Facility with Grand Opening July 10, 2012
Disruptive technology for Transportation … rail, marine, road, mining
Growth opportunity for telecommunications, uninterruptible power supplies, smart grid Novel chemistry and materials creating a $1B business
Sodium Metal Halide Battery
220,000 ft facility $150M+ factory investment
3 SECA Annual Workshop
July 2012
Anode Supported Solid Oxide Fuel Cell Layer Function Material Thickness
Air S
ide
Interconnect Gas & Electron Transport Ferritic Stainless Steel 500 m
Protective Coating Prevent interconnect Cr from
poisoning cathode (Mn,Co)3O4 10 m
Cathode Contact Paste
Electrically connect cell with air interconnect
(La,Sr)CoO3 100 m
Cathode Air electrode (La,Sr)(Co,Fe)O3 40 m
Barrier Layer Prevent cathode Sr from
reacting with electrolyte Zr
GDC (Ce0.8Gd0.2)O2
10 m
Electrolyte Permit O2- transport, prevent
air/fuel mixing
YSZ (ZrO2 + 8 mol Y2O3)
10 m
Fu
el S
ide
Functional Anode Fuel electrode NiO/YSZ 20 m
Porous Support Mechanically supports Anode
& Electrolyte Ferritic Stainless Steel
500 m
Interconnect Gas & Electron Transport Ferritic Stainless Steel
4 SECA Annual Workshop
July 2012
Metal supported cell
Advantages: Integrated anode seal Electrolyte in compression Improved anode electrical
contact Increased active area Lower anode polarization Allows redesign of structures
Challenges: Dense / hermetic electrolyte Porous metal substrate degradation
5 SECA Annual Workshop
July 2012
Low-cost manufacturing
Thermal Spray
Extrusion Lamination
Electrolyte
Electrode Layers
Thin Electrolyte Bilayer
Cutting Sintering Electrode
Application Firing
Sintered Cell Manufacturing
Leverage GE thermal spray expertise
Sheet Metal Fab Joining
Complete Interconnect
PreSealing Stacking Advantages
Larger area / Scalable Simplified sealing Low Capex / Modular Lean Manufacturing
6 SECA Annual Workshop
July 2012
Thermal spray manufacturing challenges
Thin & dense (on porous substrate)
Crack-free / hermetic strength, residual stress Edge sealing Mechanical design
Thermal management
Electrolyte functions: 1) Transport O2- ions 2) Separate air/fuel
interconnect
fuel
support
anode
electrolyte
air
interconnect
fuel
support
anode
electrolyte
air
porous cathode
dense electrolyte
porous anode
7 SECA Annual Workshop
July 2012
Smooth Anode Summary
Full coating coverage
Low-roughness coating
Key to thin, dense, crack-free electrolyte is high-quality anode
8 SECA Annual Workshop
July 2012
2” cell (25 cm2) test Set-Up
2” vehicle representative of stackable architecture
9 SECA Annual Workshop
July 2012
OCV Testing
2” cell demonstrated with good OCV
High OCV indicative of dense, crack-free coating
Spray Manufacturing Date
10 SECA Annual Workshop
July 2012
Influence of Thermal Spray Conditions on Coating Quality
Thermal spray conditions significantly impact coating quality
Good quality Poor quality
11 SECA Annual Workshop
July 2012
Power Curve Repeatability
Repeatable cell performance from run to run
12 SECA Annual Workshop
July 2012
Fuel Utilization Curve
Flow-field optimization will lead to improved fuel utilization
13 SECA Annual Workshop
July 2012
Thermal Sprayed Barrier Layer Need
Process in place for anode, electrolyte and cathode -Need to develop ceria barrier layer process
14 SECA Annual Workshop
July 2012
Flowability Measurements
Angle of Repose • Measure steepest angle of poured pile • Carr Index from ASTM D6393-08
Compressibility Index • Ratio of poured density to packed
density (Hausner Ratio)
Hall Flow • Time to flow through orifice • Use Carney funnel (0.20”) • ASTM standard B213-03
15 SECA Annual Workshop
July 2012
Flowability Data
Particle sizes, size distributions, morphology, … influence flowability
16 SECA Annual Workshop
July 2012
Ceria Barrier Layer
Addition of barrier layer significantly reduces degradation rate Longer duration testing required to validate degradation
17 SECA Annual Workshop
July 2012
Process Control
Transfer function developed to indicate hardware end-of-life
Deposition efficiency used to establish process specifications & control
18 SECA Annual Workshop
July 2012
4 pt bend test of thermal sprayed coatings to determine modulus,
failure criteria
0 1 2 3 4 5 60
5
10
15
20
25
30
35
Deflection in mm
Forc
e in N
E - Foam + 5 Heat cycles / Feb 2012
G - APS YSZ (NO Infil.) + 5 heat / Feb 2012
G - APS YSZ (NO Infil.) - OLD / Dec 2011
APS YSZ (WITH Infil.) / Dec 2011
Mechanical Characterization of SOFC materials
Mechanical properties determined experimentally for modeling
19 SECA Annual Workshop
July 2012
Heat transfer analysis of
the thermal spray
process for a 2” cell
Geometry
OCT 26 2011
15:12:55
NODAL SOLUTION
STEP=50
SUB =1
TIME=50
S3 (AVG)
PowerGraphics
EFACET=1
AVRES=Mat
DMX =.001124
SMN =-.305E+09
SMX =-.401E+08
DSYS=4
1
MN
MX
X
Y
Z
ZV =1
*DIST=.05141
*XF =.034488
*YF =.046789
*ZF =-.0062
Z-BUFFER
-.305E+09
-.275E+09
-.246E+09
-.217E+09
-.187E+09
-.158E+09
-.128E+09
-.989E+08
-.695E+08
-.401E+08
Min prin. Temp dist.
Thermo-mechanical Modeling of SOFC Components
20 SECA Annual Workshop
July 2012
Comparison of thermal management stress state
Thermal management impacts coating stress state
Good thermal management Poor thermal management
0
0 0 0
21 SECA Annual Workshop
July 2012
Scale-up (25 cm2 to 100 cm2)
Thermal management important in scaling from 2” to 4”
22 SECA Annual Workshop
July 2012
Summary
• Developed thermal spray conditions and suitable substrate to enable high OCV
• Scaled thermal spray manufacturing from 2.85 cm2 to 25 cm2 to 100 cm2
• Demonstrated thermal sprayed barrier layer
• Establishing thermal spray process control metrics
• Evolved thermo-mechanical FE models to support development and scale-up
23 SECA Annual Workshop
July 2012
Acknowledgements
• Joe Stoffa, Heather Quedenfeld and Dan Driscoll of DOE/NETL
• SECA partners
• GE SOFC Team
• Funding provided by the US Department of Energy through cooperative agreement DE-NT0004109.
This material is based upon work supported by the Department of Energy under Award Number DE-NT0004109. However, any opinions, findings, conclusions, or
recommendations expressed herein are those of the authors and do not necessarily
reflect the views of the DOE.