Laser additive manufacturing of functional metallic components for solid oxide fuel cells

With the development of solid oxide fuel cells (SOFC) for mid-to-low temperature operation, the proportion of metal as cost-effective and vital structural components gradually increases. Laser additive manufacturing (LAM) provides considerable design and manufacturing flexibility and is applicable to SOFC metallic components. In this work, Fe-Cr alloys are fabricated using LAM to investigate the effect of Cr content on thermal compatibility and mechanical properties, as well as to evaluate their performance as SOFC interconnects and supports. The results indicate that both 430 (Fe16Cr) and Fe24Cr preserve a stable composition and phase structure. The dense Fe24Cr specimens exhibit good thermal compatibility, mechanical strength, and high-temperature oxidation resistance. Following 1,000 h of cyclic oxidation, the weight gain of Fe24Cr is markedly inferior to that of 430 and sustains a minimal area-specific resistance of 8.5 m Omega cm2 at 800 degrees C. Additionally, porous 430 and Fe24Cr exhibit favorable compatibility with SOFC functional layers. As results, the single cells supported by 430 and Fe24Cr exhibit excellent electrochemical performance, achieving maximum power densities of 1,154 mW cm-2 and 1,168 mW cm-2 at 800 degrees C, respectively. This work highlights the potential of LAM in fabricating highperformance metallic components for SOFC.