Novel Dry Powder Processing Routes for Porous Anode Supports in Solid Oxide Electrochemical Cells

This research investigates fabrication of porous anode supports for solid oxide cells using yttria- stabilized zirconia (3YSZ) ceramics, seeking optimal compaction pressure by correlating microstructure with mechanical properties. Three formulations were studied: base 3YSZ with organic additives; 3YSZ with graphite as pore-former; and a complete anode support with 3YSZ, NiO, and graphite. Samples underwent uniaxial pressing (10-60 MPa) followed by sintering. Microstructure was analyzed via X-ray tomography to quantify porosity and connectivity, while mechanical properties were measured using ball-on-ring tests. Results show higher compaction pressures reduce porosity and pore connectivity while improving mechanical strength. Graphite-based supports exhibited greater pore interconnectivity, beneficial for infiltration, whereas NiO-containing samples were denser even at lower compaction pressures. This study demonstrates how processing parameters influence the critical balance between gas permeability and mechanical integrity for optimized SOC components