Field Enhanced Sintering: process development for Steel Cell- Solid Oxide Fuel Cells

Ceramic bodies, such as those found in steel cell Solid Oxide Fuel Cells (SOFC's), are produced by sintering green parts at high temperatures. This project looks to assess and demonstrate the use of Field Enhanced Sintering (FES) technology as a process to improve the productivity of SOFC manufacture. FES is the application of electric fields to ceramics during their sintering process, it has been shown to dramatically reduce sintering times used in ceramic manufacture, as well as improve the properties of the end material via microstructural control. Fuel cells can be used in Combined Heat and Power (CHP) generators, as range extenders on automobiles, and as power generators for data storage facilities. They are broadly acknowledged to be the most efficient way to generate heat and electricity from renewable sources, however, the commercial challenge lies in their affordability for end application. The limiting factors here are speed and cost of manufacture, this is due to the extensive sintering steps required for each constituent material. This project, via a UK consortium of two SME's, Lucideon and Ceres Power, aims to address this commercial need for mutual benefit, by overcoming this challenge. The application of FES technology to SOFC manufacture is a highly technical and innovate step. Never before has an attempt been made to sinter this combination of materials, using FES, nor in a single step before. The project's objectives is to significantly reduce the sintering time for SOFC ceramics, thus increasing throughput and making steel cell SOFC technology a world leader within this sector. Also, via FES's ability to provide microstructural control, the performance of the materials within an operating environment shall be enhanced and verified. The project will utilise and build upon existing propriety control software (digital manufacturing), to control the field application to the SOFC materials, and ensure efficient sintering joining of dissimilar materials via prototype electrode and furnace design. The project aims to demonstrate FES application for the production of a commercial sized Steel Cell-SOFC part, along with performance verification against the current state-of-the-art. The project provides an opportunity for the consortium to advance a low TRL process to address growing national & international challenges in low carbon technology for energy generation, transport and manufacturing, contributing to creation of world leading reputations for the UK in each area