Optimization of laser-patterned YSZ-LSM composite cathode-electrolyte interfaces for solid oxide fuel cells

Patterned cathode/electrolyte interfaces formed by a hexagonal array of ∼22 μm deep wells with 24 μm lattice parameter have been prepared by pulsed laser machining to enlarge the contact surface and, consequently, to reduce the cathode polarization of Solid Oxide Fuel Cells. These new interfaces have been tested in YSZ-LSM/YSZ/YSZ-LSM symmetrical cells, where the cathode is deposited by dip-coating. Appropriate ceramic suspensions have been formulated to penetrate into deep wells without presenting interfacial delamination after sintering. We analyse their applicability by comparing their rheology with the microstructure and electrochemical performance of the cells. The activation component of the polarization resistance is reduced by ∼50% using ethanol-based suspensions with 20 wt% solids loading, although the gas diffusion component increases due to excessive densification. Alternative ceramic suspensions with 17.5 wt% solids loading provide optimum electrode gas diffusion but lower activation components, resulting in an overall decrease of ∼20% in polarization resistance.