Enhancing Protonic Ceramic Fuel Cells by Advanced Laser Processing for Superior Performance

As global temperatures rise, the demand for clean energy solutions intensifies. Protonic ceramic fuel cells (PCFCs) offer advantages like higher conductivity at moderate temperatures (300–700 °C), fuel flexibility, stability, and lower costs. However, traditional PCFC manufacturing faces challenges with interface defects, structural imperfections, and scalability, especially in producing large-area cells and stacks. This work addresses these issues using advanced laser processing techniques. Laser ablation and direct laser rapid additive manufacturing (DL-RAM) enable precise control of PCFC microstructures, removing surface defects and increasing bonding strength for higher efficiency. Digital layer deposition allows for large-area PCFC single cells and stack production with controlled geometry and layer thickness, while rapid laser reactive sintering (RLRS) replaces traditional sintering, reducing processing time. Additionally, a segmented-in-series stack design enhances power output without compromising peak power density. These advancements significantly improve PCFC performance, extending their potential to other energy applications like solid oxide cells, electrolyzers, and solid-state batteries.