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SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC SOFC 13 th Annual SECA Workshop Pittsburgh, PA July 24-25, 2012
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Page 1: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

SOFC Manufacturing Development at GE Global

Research Matt Alinger GE Global Research Niskayuna, NY

SOFCSOFC

13th Annual SECA Workshop Pittsburgh, PA July 24-25, 2012

Page 2: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

2 SECA Annual Workshop

July 2012

GE Unveils Advanced-Manufacturing Battery Facility with Grand Opening July 10, 2012

Disruptive technology for Transportation … rail, marine, road, mining

Growth opportunity for telecommunications, uninterruptible power supplies, smart grid Novel chemistry and materials creating a $1B business

Sodium Metal Halide Battery

220,000 ft facility $150M+ factory investment

Page 3: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

3 SECA Annual Workshop

July 2012

Anode Supported Solid Oxide Fuel Cell Layer Function Material Thickness

Air S

ide

Interconnect Gas & Electron Transport Ferritic Stainless Steel 500 m

Protective Coating Prevent interconnect Cr from

poisoning cathode (Mn,Co)3O4 10 m

Cathode Contact Paste

Electrically connect cell with air interconnect

(La,Sr)CoO3 100 m

Cathode Air electrode (La,Sr)(Co,Fe)O3 40 m

Barrier Layer Prevent cathode Sr from

reacting with electrolyte Zr

GDC (Ce0.8Gd0.2)O2

10 m

Electrolyte Permit O2- transport, prevent

air/fuel mixing

YSZ (ZrO2 + 8 mol Y2O3)

10 m

Fu

el S

ide

Functional Anode Fuel electrode NiO/YSZ 20 m

Porous Support Mechanically supports Anode

& Electrolyte Ferritic Stainless Steel

500 m

Interconnect Gas & Electron Transport Ferritic Stainless Steel

Page 4: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

4 SECA Annual Workshop

July 2012

Metal supported cell

Advantages: Integrated anode seal Electrolyte in compression Improved anode electrical

contact Increased active area Lower anode polarization Allows redesign of structures

Challenges: Dense / hermetic electrolyte Porous metal substrate degradation

Page 5: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

5 SECA Annual Workshop

July 2012

Low-cost manufacturing

Thermal Spray

Extrusion Lamination

Electrolyte

Electrode Layers

Thin Electrolyte Bilayer

Cutting Sintering Electrode

Application Firing

Sintered Cell Manufacturing

Leverage GE thermal spray expertise

Sheet Metal Fab Joining

Complete Interconnect

PreSealing Stacking Advantages

Larger area / Scalable Simplified sealing Low Capex / Modular Lean Manufacturing

Page 6: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

6 SECA Annual Workshop

July 2012

Thermal spray manufacturing challenges

Thin & dense (on porous substrate)

Crack-free / hermetic strength, residual stress Edge sealing Mechanical design

Thermal management

Electrolyte functions: 1) Transport O2- ions 2) Separate air/fuel

interconnect

fuel

support

anode

electrolyte

air

interconnect

fuel

support

anode

electrolyte

air

porous cathode

dense electrolyte

porous anode

Page 7: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

7 SECA Annual Workshop

July 2012

Smooth Anode Summary

Full coating coverage

Low-roughness coating

Key to thin, dense, crack-free electrolyte is high-quality anode

Page 8: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

8 SECA Annual Workshop

July 2012

2” cell (25 cm2) test Set-Up

2” vehicle representative of stackable architecture

Page 9: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

9 SECA Annual Workshop

July 2012

OCV Testing

2” cell demonstrated with good OCV

High OCV indicative of dense, crack-free coating

Spray Manufacturing Date

Page 10: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

10 SECA Annual Workshop

July 2012

Influence of Thermal Spray Conditions on Coating Quality

Thermal spray conditions significantly impact coating quality

Good quality Poor quality

Page 11: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

11 SECA Annual Workshop

July 2012

Power Curve Repeatability

Repeatable cell performance from run to run

Page 12: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

12 SECA Annual Workshop

July 2012

Fuel Utilization Curve

Flow-field optimization will lead to improved fuel utilization

Page 13: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

13 SECA Annual Workshop

July 2012

Thermal Sprayed Barrier Layer Need

Process in place for anode, electrolyte and cathode -Need to develop ceria barrier layer process

Page 14: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

14 SECA Annual Workshop

July 2012

Flowability Measurements

Angle of Repose • Measure steepest angle of poured pile • Carr Index from ASTM D6393-08

Compressibility Index • Ratio of poured density to packed

density (Hausner Ratio)

Hall Flow • Time to flow through orifice • Use Carney funnel (0.20”) • ASTM standard B213-03

Page 15: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

15 SECA Annual Workshop

July 2012

Flowability Data

Particle sizes, size distributions, morphology, … influence flowability

Page 16: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

16 SECA Annual Workshop

July 2012

Ceria Barrier Layer

Addition of barrier layer significantly reduces degradation rate Longer duration testing required to validate degradation

Page 17: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

17 SECA Annual Workshop

July 2012

Process Control

Transfer function developed to indicate hardware end-of-life

Deposition efficiency used to establish process specifications & control

Page 18: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

18 SECA Annual Workshop

July 2012

4 pt bend test of thermal sprayed coatings to determine modulus,

failure criteria

0 1 2 3 4 5 60

5

10

15

20

25

30

35

Deflection in mm

Forc

e in N

E - Foam + 5 Heat cycles / Feb 2012

G - APS YSZ (NO Infil.) + 5 heat / Feb 2012

G - APS YSZ (NO Infil.) - OLD / Dec 2011

APS YSZ (WITH Infil.) / Dec 2011

Mechanical Characterization of SOFC materials

Mechanical properties determined experimentally for modeling

Page 19: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

19 SECA Annual Workshop

July 2012

Heat transfer analysis of

the thermal spray

process for a 2” cell

Geometry

OCT 26 2011

15:12:55

NODAL SOLUTION

STEP=50

SUB =1

TIME=50

S3 (AVG)

PowerGraphics

EFACET=1

AVRES=Mat

DMX =.001124

SMN =-.305E+09

SMX =-.401E+08

DSYS=4

1

MN

MX

X

Y

Z

ZV =1

*DIST=.05141

*XF =.034488

*YF =.046789

*ZF =-.0062

Z-BUFFER

-.305E+09

-.275E+09

-.246E+09

-.217E+09

-.187E+09

-.158E+09

-.128E+09

-.989E+08

-.695E+08

-.401E+08

Min prin. Temp dist.

Thermo-mechanical Modeling of SOFC Components

Page 20: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

20 SECA Annual Workshop

July 2012

Comparison of thermal management stress state

Thermal management impacts coating stress state

Good thermal management Poor thermal management

0

0 0 0

Page 21: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

21 SECA Annual Workshop

July 2012

Scale-up (25 cm2 to 100 cm2)

Thermal management important in scaling from 2” to 4”

Page 22: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

22 SECA Annual Workshop

July 2012

Summary

• Developed thermal spray conditions and suitable substrate to enable high OCV

• Scaled thermal spray manufacturing from 2.85 cm2 to 25 cm2 to 100 cm2

• Demonstrated thermal sprayed barrier layer

• Establishing thermal spray process control metrics

• Evolved thermo-mechanical FE models to support development and scale-up

Page 23: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

23 SECA Annual Workshop

July 2012

Acknowledgements

• Joe Stoffa, Heather Quedenfeld and Dan Driscoll of DOE/NETL

• SECA partners

• GE SOFC Team

• Funding provided by the US Department of Energy through cooperative agreement DE-NT0004109.

This material is based upon work supported by the Department of Energy under Award Number DE-NT0004109. However, any opinions, findings, conclusions, or

recommendations expressed herein are those of the authors and do not necessarily

reflect the views of the DOE.

Page 24: SOFC Development at GE Global Research · SOFC Manufacturing Development at GE Global Research Matt Alinger GE Global Research Niskayuna, NY SOFC 13th Annual SECA Workshop Pittsburgh,

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