Study on the influence of different preparation methods on the micro-structure and electrical properties of dense BZY ceramics

Barium Zirconate Yttria (BZY) has garnered significant attention in the development of Protonic Ceramic Fuel Cells (PCFCs) due to its high chemical stability and bulk proton conductivity. However, BZY powders synthesized using traditional solid-state methods exhibit a broad particle size distribution and poor sintering activity, limiting their application potential in PCFCs. This study compares the performance differences between Tape Casting&Reactive Sintering(TCRS) and traditional methods in preparing dense BZY ceramics, evaluating the impact on micro-structure and conductivity. Experimental results demonstrate that BZY dense ceramics prepared via TCRS exhibit superior properties, with a conductivity of 2.41 × 10⁻³ S·cm⁻¹ at 600 °C, higher than those produced by Dry Pressing&Reactive Sintering(DPRS) and Tape Casting&Sintering(TCS) methods. This technique not only simplifies the preparation process and reduces costs but also enhances conductivity, showing significant potential for scaled-up production. Therefore, TCRS provides an efficient and cost-effective solution for the high-performance preparation of electrolyte materials for PCFCs, advancing the practical application of BZY ceramics in fuel cell technology.