Testing of solid-oxide fuel cells for micro to macro power generation

Thin film, solid-oxide fuel cells (TFSOFCs) are developed using photolithographic patterning and physical vapor deposition. In this study, both electrode layers of nickel (Ni) and silver (Ag) as well as the solid-oxide electrolyte layer of yttria-stabilized zirconia (YSZ) are synthesized on the micrometer scale for thickness. The anode layer enables combination of the reactive gases, is conductive to pass the electric current, and provides mechanical support to the electrolyte and cathode layers. The morphology desired for both the anode and cathode layers facilitates generation of maximum current density from the fuel cell. For these purposes, the parameters of the deposition process and postdeposition patterning are optimized for continuous porosity across both electrode layers. The electrodes are characterized using scanning electron microscopy and the power output generated through current-voltage measurement. We find that a TFSOFC based on Ni-YSZ-Ag can be operated with dilute fuel mixtures at temperatures below 300 degrees C.