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<p>La<sub>0</sub>.<sub>6</sub>Sr<sub>0</sub>.<sub>4</sub>Co<sub>0</sub>.<sub>2</sub>Fe<sub>0</sub>.<sub>8</sub>O<sub>3−δ</sub> (LSCF) has been widely employed as a cathode and current collector material for tubular segmented-in-series solid oxide fuel cells (Tubular-SIS-SOFCs), yet plasma-sprayed LSCF current collector layers (CCLs) often suffer from insufficient gas permeability and performance degradation caused by B-site element evaporation in high-temperature plasma jets, while conventional noble-metal current collectors increase cost and compromise long-term stability. In this work, a composite strategy was developed by incorporating transition-metal particles into LSCF feedstock via atmospheric plasma spraying (APS) to construct a noble-metal-free ceramic CCL. Due to poor wettability between overheated metal droplets and LSCF splats, metallic particles solidified in a dispersed morphology within the coating. During subsequent heat treatment, in situ oxidation-induced volumetric expansion of metal particles promoted controlled crack propagation, enhancing gas diffusion pathways, while thermally driven metal-ion diffusion partially compensated B-site depletion and restored lattice conductivity. Systematic investigation revealed that the LSCF-5Fe coating fabricated at 25&#xa0;kW achieved an optimal balance between gas permeability, mechanical integrity, and electrical conductivity. Among different metals, LSCF-5Cu exhibited the highest post-treatment conductivity of 100.5 S cm<sup>−1</sup>. Tubular-SIS-SOFCs employing metal-particle-modified LSCF CCLs delivered over 50% higher maximum power output compared with pure LSCF counterparts, accompanied by significantly reduced polarization resistance and stable thermal cycling performance. These results demonstrate a scalable and cost-effective strategy for replacing noble-metal current collectors and enabling high-power tubular-SIS-SOFCs.</p>

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Metal-Particle-Modified LSCF Current Collector Layers Fabricated by Atmospheric Plasma Spraying for High-Power Tubular Segmented-in-Series SOFCs

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Zi-Yang Chen,
  • Xin Zhang,
  • Yan-Neng Liang,
  • Chang-jiu Li,
  • Cheng-Xin Li

摘要

La0.6Sr0.4Co0.2Fe0.8O3−δ (LSCF) has been widely employed as a cathode and current collector material for tubular segmented-in-series solid oxide fuel cells (Tubular-SIS-SOFCs), yet plasma-sprayed LSCF current collector layers (CCLs) often suffer from insufficient gas permeability and performance degradation caused by B-site element evaporation in high-temperature plasma jets, while conventional noble-metal current collectors increase cost and compromise long-term stability. In this work, a composite strategy was developed by incorporating transition-metal particles into LSCF feedstock via atmospheric plasma spraying (APS) to construct a noble-metal-free ceramic CCL. Due to poor wettability between overheated metal droplets and LSCF splats, metallic particles solidified in a dispersed morphology within the coating. During subsequent heat treatment, in situ oxidation-induced volumetric expansion of metal particles promoted controlled crack propagation, enhancing gas diffusion pathways, while thermally driven metal-ion diffusion partially compensated B-site depletion and restored lattice conductivity. Systematic investigation revealed that the LSCF-5Fe coating fabricated at 25 kW achieved an optimal balance between gas permeability, mechanical integrity, and electrical conductivity. Among different metals, LSCF-5Cu exhibited the highest post-treatment conductivity of 100.5 S cm−1. Tubular-SIS-SOFCs employing metal-particle-modified LSCF CCLs delivered over 50% higher maximum power output compared with pure LSCF counterparts, accompanied by significantly reduced polarization resistance and stable thermal cycling performance. These results demonstrate a scalable and cost-effective strategy for replacing noble-metal current collectors and enabling high-power tubular-SIS-SOFCs.