Due to their direct conversion of electrochemical into electrical energy solid oxide fuel cells (SOFCs)
have great potential for a future additional energy supply. Even in the last two years numerous
developers of SOFCs, both industry and research institutions, have demonstrated long-term stable
operation of stacks of various dimensions (ranging from 1 to 125 kWel, with durations of up to 25000
hours of operation). Besides technical proof, single component availability (cells, bipolar plates,
sealing…), stable and low-aging operation, as well as cost efficient manufacturing of the components
is becoming more and more evident in preparation for a market launch.
Close cooperation between SOFC stack developers, SOFC users and manufacturers of powders, semifinished
parts or stack components is a prerequisite for success.
Within a collaboration project funded by the German Federal Ministry of Economics and Labor
(BMWA) the development of an SOFC as an auxiliary power unit (APU) is being promoted. The
industrial users are BMW for automotive applications and Liebherr for use in construction vehicles or
aircraft.
The content of this presentation will be the transfer of the manufacturing knowledge developed at
Research Center Jülich to CeramTec; including on the one hand the problems and limitations and, on
the other hand the successes and positive perceptions. In detail, the transfer of, for example tape
casting and screen printing will be addressed, powder characteristics concerning paste or slip
formulation and special tests with reference to SOFCs are presented, and single cell tests of various
cells manufactured with different powders or fabrication processes are described.
Additionally, some remarks will concern different priorities in either R&D or industry (e.g. R&D:
high power density; industry: reproducibility), process windows for manufacturing and the search for
alternative fabrication methods.