Synthesis of Octahedral-Shaped NiO and Approaches to an Anode Material of Manufactured Solid Oxide Fuel Cells Using the Decalcomania Method

Micrometer-sized and octahedral-shaped NiO particles were synthesized by microwave thermal treatment at 300 watt power for 15 min in a microwave chamber to be used as an anode material in solid oxide fuel cells. SEM image and particle size distribution revealed near-perfect octahedral NiO microparticle with sizes ranging from 4.0~11.0 μm. The anode functional layer (AFL, 60 wt% NiO synthesized: commercial 40 wt% YSZ), electrolyte (commercial Yttria-stabilized zirconia, YSZ), and cathode (commercial La0.8Sr0.2MnO3, LSM) layers were manufactured using the decalcomania method on a porous anode support, sequentially. The sintered electrolyte at 1450°C for 2 h using the decalcomania method was dense and had a thickness of about 10 μm. The cathode was sintered at 1250°C for 2 h, and it was porous. Using humidified hydrogen as a fuel, a coin cell with a 15 μm thick anode functional layer exhibited maximum power densities of 0.28, 0.38, and 0.65 W/cm2at 700, 750, and 800°C, respectively. Otherwise, when a commercial YSZ anode functional layer was used, the maximum power density was 0.55 W/cm2at 800°C.