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All-sputtered protonic ceramic fuel cells based on flashlight-sintered thin-film Y:BaZrO3-δ electrolyte

Jiwon Baek, Junseo Youn, Hyoun-Myoung Oh, Jonghyuk Lee, Haesu Lee, Nguyen Q. Minh, Young-Beom Kim*, Yoon Ho Lee*, Taehyun Park*

https://doi.org/10.1016/j.cjsc.2025.100598

ABSTRACT

In this work, we present an innovative method for fabricating high-performance proton-conducting ceramic fuel cells (PCFCs) by combining magnetron sputtering and flashlight sintering (FLS) techniques. BaZr0.8Y0.2O3-δ (BZY20) electrolyte thin films were successfully prepared by improving the crystallinity while maintaining the stoichiometry. All components of the PCFC, the Ni-YSZ anode, BZY20 electrolyte, and Pt-GDC cathode, were fabricated by sequentially sputtering them onto an AAO substrate. Electrolytic sintering was performed at 550 V and 650 V conditions using FLS, effectively solving the barium evaporation problem encountered in conventional thermal sintering methods. XRD analysis confirmed that the perovskite structure was retained, and crystallinity was improved in the FLS samples. Furthermore, FE-SEM and EDS analyses confirmed the uniform elemental distribution and consistent thickness of the FLS-treated electrolyte. An optimized PCFC unit cell with FLS-treated electrolyte exhibited a peak power density of 200.0 mW cm-2 at 500 °C and an ohmic resistance of 376.0 mΩ cm-2. These results suggest that the combination of magnetron sputtering and FLS techniques is a promising approach for fabricating high-performance thin-film PCFCs.

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