Low-cost fabrication of high-performance anode-supported SOFCs with anti-carbon deposition capability

• A cost-effective anode-supported SOFC with excellent gas-tightness is developed. • NiO-YSZ anode exhibits high porosity with a robust framework for electrochemical reactions. • H 2 -powered SOFC achieves a peak power density of 1.408 W/cm² at 1000 °C. • CH 4 -powered SOFC reaches a peak power density of 0.96 W/cm² at 1000 °C. • CH 4 -powered SOFC demonstrates excellent resistance to carbon deposition based on gas analysis. The development of cost-effective solid oxide fuel cells (SOFCs) is crucial for the large-scale application. In this study, anode-supported SOFC single cells were fabricated using a combination of slurry spraying and spin-coating technique to achieve a dense Yttria Stabilized Zirconia (YSZ) electrolyte layer while maintaining low production cost. The electrochemical performance of the fabricated SOFC was evaluated using hydrogen and dry methane as fuels. Microstructural analysis confirmed that the YSZ electrolyte exhibited high densification with a thickness of approximately 10 μm, ensuring excellent gas-tightness and preventing fuel crossover. The NiO-YSZ anode demonstrated favorable porosity, with well-sintered NiO particles forming a robust framework to facilitate electrochemical reactions. Performance evaluations revealed that under hydrogen operation, the SOFC achieved a peak power density of 1.408 W/cm² at 1000 °C, with open-circuit voltages (OCVs) closely matching theoretical predictions. When operated with dry methane, the SOFC maintained stable performance, reaching a peak power density of 0.96 W/cm² at 1000 °C, highlighting its potential for direct hydrocarbon utilization. Gas composition analysis of the anode exhaust confirmed the absence of excessive carbon deposition, indicating the effectiveness of the anode microstructure in mitigating coking during methane oxidation. These findings demonstrate that the spray-coated and spin-coated SOFC design offers a promising approach to improving fuel cell efficiency and cost-effectiveness. Future research should focus on optimizing electrolyte fabrication methods and enhancing anode stability in hydrocarbon-fueled operation to further advance the commercialization of SOFC technology.