Development of zirconia electrolyte films on porous doped lanthanum manganite cathodes by electrophoretic deposition

Electrophoretic deposition (EPD) was explored as an inexpensive route for fabricating the 8mol% yttria stabilized zirconia electrolyte in solid oxide fuel cells (SOFCs). Normally, deposition of particulate ceramic powders onto a sintered porous surface yields a non uniform coating which, after sintering, results in porosity, surface roughness and cracking in the coating. To overcome this problem, the present study used a fugitive graphite interlayer between the porous air electrode supported (AES) cathode tube (doped-LaMnO₃) and the deposited zirconia film. By this approach, a fairly dense green coating (∼ 60%) was obtained, which yielded a smooth surface and pore-free microstructure after sintering. Preliminary results on the effect of a fugitive interlayer on the unfired (green) and fired zirconia coatings are discussed.