Lowering the sintering temperature of BaZr0.4Ce0.4Y0.1Yb0.1O3-δ electrolyte by spark plasma sintering for protonic ceramic fuel cells

Protonic ceramic fuel cells (PCFCs) necessitate dense electrolytes to minimize grain boundary resistance and effectively isolate the atmospheres of the electrodes, typically requiring high densification temperatures exceeding 1500 °C. Such conditions can result in anode sintering and the volatilization of Ba. To address these challenges, a promising alternative, spark plasma sintering (SPS) technology characterized by high thermal efficiency and uniform heating, was proposed. This study marks the inaugural application of SPS in the fabrication of anode-supported PCFCs. Single cells prepared using the SPS process demonstrated peak power densities of 0.802 and 0.526 W cm⁻² at 650 and 600 °C, respectively. These results represent a substantial improvement in electrochemical performance compared to cells produced via traditional high-temperature co-sintering methods. The enhancement is attributed to the increased specific surface area and porosity of the anode. Furthermore, PCFCs fabricated with the SPS process exhibit exceptional stability. In conclusion, a novel method was provided for preparing PCFC single cells that not only effectively reduces sintering costs and time but also significantly enhances the electrochemical performance of the cells.