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 yttriastabilized 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.