Plasma-sprayed 3.9YSZ porous coatings with mille-feuille structure and high composite porosity for SOFC applications

Hann Pyng Wu; Kuan Zong Fung

doi:10.1016/j.surfcoat.2013.04.019

Plasma-sprayed 3.9YSZ porous coatings with mille-feuille structure and high composite porosity for SOFC applications

Research output: Contribution to journal › Article › peer-review

Abstract

A porous coating process for direct-oxidation solid oxide fuel cell (SOFC) electrodes that reduces manufacturing costs and production time is proposed. The process uses Al alloy-polyester as a pore former to create a mille-feuille structure and high porosity in plasma-sprayed 3.9mol% yttria-stabilized zirconia (3.9YSZ) coatings. With an insufficient amount of pore former (35vol.%), the as-sprayed coating surface has a higher surface roughness (R_a=12-13μm). When a sufficient amount of pore former (50vol.%) is used, the as-sprayed coating surface roughness (R_a) is 10-11μm. Apparent porosities in the range of 41.2 to 56.4vol.% are obtained for the etched and burned plasma sprayed coating. The porosity created with a sufficient amount of pore former (50vol.%) is significantly higher than that created with an insufficient amount (35vol.%). The monoclinic phase originally in the 3.9YSZ feedstock powder almost completely disappears after plasma spraying.

Original language	English
Pages (from-to)	132-139
Number of pages	8
Journal	Surface and Coatings Technology
Volume	228
DOIs	https://doi.org/10.1016/j.surfcoat.2013.04.019
Publication status	Published - 2013 Aug 15

All Science Journal Classification (ASJC) codes

Chemistry(all)
Condensed Matter Physics
Surfaces and Interfaces
Surfaces, Coatings and Films
Materials Chemistry

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@article{f713f4152c97420c9051233586568052,

title = "Plasma-sprayed 3.9YSZ porous coatings with mille-feuille structure and high composite porosity for SOFC applications",

abstract = "A porous coating process for direct-oxidation solid oxide fuel cell (SOFC) electrodes that reduces manufacturing costs and production time is proposed. The process uses Al alloy-polyester as a pore former to create a mille-feuille structure and high porosity in plasma-sprayed 3.9mol% yttria-stabilized zirconia (3.9YSZ) coatings. With an insufficient amount of pore former (35vol.%), the as-sprayed coating surface has a higher surface roughness (Ra=12-13μm). When a sufficient amount of pore former (50vol.%) is used, the as-sprayed coating surface roughness (Ra) is 10-11μm. Apparent porosities in the range of 41.2 to 56.4vol.% are obtained for the etched and burned plasma sprayed coating. The porosity created with a sufficient amount of pore former (50vol.%) is significantly higher than that created with an insufficient amount (35vol.%). The monoclinic phase originally in the 3.9YSZ feedstock powder almost completely disappears after plasma spraying.",

author = "Wu, {Hann Pyng} and Fung, {Kuan Zong}",

year = "2013",

month = aug,

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doi = "10.1016/j.surfcoat.2013.04.019",

language = "English",

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pages = "132--139",

journal = "Surface and Coatings Technology",

issn = "0257-8972",

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T1 - Plasma-sprayed 3.9YSZ porous coatings with mille-feuille structure and high composite porosity for SOFC applications

AU - Wu, Hann Pyng

AU - Fung, Kuan Zong

PY - 2013/8/15

Y1 - 2013/8/15

N2 - A porous coating process for direct-oxidation solid oxide fuel cell (SOFC) electrodes that reduces manufacturing costs and production time is proposed. The process uses Al alloy-polyester as a pore former to create a mille-feuille structure and high porosity in plasma-sprayed 3.9mol% yttria-stabilized zirconia (3.9YSZ) coatings. With an insufficient amount of pore former (35vol.%), the as-sprayed coating surface has a higher surface roughness (Ra=12-13μm). When a sufficient amount of pore former (50vol.%) is used, the as-sprayed coating surface roughness (Ra) is 10-11μm. Apparent porosities in the range of 41.2 to 56.4vol.% are obtained for the etched and burned plasma sprayed coating. The porosity created with a sufficient amount of pore former (50vol.%) is significantly higher than that created with an insufficient amount (35vol.%). The monoclinic phase originally in the 3.9YSZ feedstock powder almost completely disappears after plasma spraying.

AB - A porous coating process for direct-oxidation solid oxide fuel cell (SOFC) electrodes that reduces manufacturing costs and production time is proposed. The process uses Al alloy-polyester as a pore former to create a mille-feuille structure and high porosity in plasma-sprayed 3.9mol% yttria-stabilized zirconia (3.9YSZ) coatings. With an insufficient amount of pore former (35vol.%), the as-sprayed coating surface has a higher surface roughness (Ra=12-13μm). When a sufficient amount of pore former (50vol.%) is used, the as-sprayed coating surface roughness (Ra) is 10-11μm. Apparent porosities in the range of 41.2 to 56.4vol.% are obtained for the etched and burned plasma sprayed coating. The porosity created with a sufficient amount of pore former (50vol.%) is significantly higher than that created with an insufficient amount (35vol.%). The monoclinic phase originally in the 3.9YSZ feedstock powder almost completely disappears after plasma spraying.

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