Effect of open pore and pore interconnectivity in the Ni-SDC cermet anode microstructure on the performance of solid oxide fuel cells

In nickel-samarium-doped ceria (Ni-SDC) cermet anode layers, the open pores and interconnected pores in the microstructure are the main factors that affect the mechanical and electrical properties. In this work, porous Ni-SDC cermet anode layers are fabricated using various quantities of potato starch (0 to 25 wt.%) as a pore forming in the anode powders. The properties of the Ni-SDC cermet anode layers were characterised by FESEM-BSE microscopy, Archimedes method for density measurement, Vickers hardness, flexural strength, and DC four-point electrical conductivity. The findings revealed that the different content of potato starch greatly affected the percentage of porosity and pore interconnectivity in the microstructure and consequently altered the mechanical and electrical properties of the Ni-SDC cermet anode. The degree of shrinkage, relative density, mechanical strength and electrical conductivity of the Ni-SDC cermet anodes decreased as their pore former content increased. Furthermore, the research shows that the large porosity (> 40%) in the Ni-SDC cermet anode microstructure affected the continuity of Ni-Ni, SDC and Ni-SDC phases and thereby affected the mechanical and electrical properties. The Ni-SDC cermet anode with 10 wt.% exhibited sufficient porosity, Vickers hardness, flexural strength and electrical conductivity of 34%, 48 MPa, 72 MPa and 2028 S/cm (at 800 °C), respectively. Therefore, optimisation of porosity in the Ni-SDC cermet anode microstructure strongly contributes to the well-connected pore channels for the rapid diffusion of hydrogen for oxidation and mechanical strength.