A new method for fabrication of metal-cermet anodes in solid-oxide fuel cel
ls (SOFCs) has been developed. Highly porous, yttria-stabilized zirconia (Y
SZ) films were prepared using a mixture of zircon fibers (YSZp, Si-stabiliz
ed, and <0.3% Si) and normal YSZ powders (YSZd). The films remained highly
porous following calcination up to 1550 degrees C, after which either Cu or
Ni could be incorporated by impregnation with the nitrate salts. For Cu ce
rmets, the performance increased with metal loading to at least 40% Cu. At
800 degrees C using H-2 as the fuel and a 230 mu m, YSZ electrolyte, the cu
rrent-voltage (I-V) curves for either a Cu- or Ni-cermet anode formed using
this new method were found to be identical to the I-V curve for a Ni cerme
t formed using traditional methods. Scanning electron microscopy showed tha
t the anode films remained porous even with addition of Cu, so that additio
nal modification was possible. Tests of this concept through the addition o
f ceria by impregnation with the Ce(NO3)(3) led to an additional increase i
n the cell performance. (C) 1999 The Electrochemical Society. S0013-4651(99
)04-074-4. All rights reserved.