LAUSR

Abstract We examine ceramic tape-casting and anode electrolyte co-firing for large-scale manufacturing of protonic ceramic fuel cells. We confirm the reactivity of Ni, a commonly used anode, with BaZr0.8M0.2O3−δ (BZM20: M = Sc, In, Lu, Yb, Y or Gd). Addition of 0.4 mol% NiO to BZM20 and co-firing at 1778 K, produces BaM2NiO5 for M = Y and Gd. No reaction occurs for M = Sc, In, Lu and Yb. The proton conductivity of all BZM20s decreases by approximately 30% because of NiO doping and dehydration on dissolution NiO. Energy efficiency and power density calculations of the fuel cells based on measured proton and hole conductivities indicate respective decreases of approximately 10% and 75% ecause of the formation of a solid solution of NiO. We fabricate fuel cells by the tape-casting and anode electrolyte co-firing with BZM20 (M = Yb or Y). For M = Y, the cell cannot be fabricated because formation of BaY2NiO5 causes cell cracking. Conversely, when M = Yb, a cell with a maximum output of 0.5 Wcm−2 at 873 K is fabricated. Hence, BZYb20 is a suitable material for tape-casting and anode electrolyte co-firing.