Hydration-induced stiffness enabling robust thermal cycling of high temperature fuel cells cathode

Hongxin Yang, Yuan Zhang (), Zhipeng Liu, Chunfang Hu, Junbiao Li, Hailong Liao, Minhua Shao, Meng Ni, Bin Chen (), Zongping Shao () and Heping Xie ()
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Hongxin Yang: Shenzhen University
Yuan Zhang: Clear Water Bay
Zhipeng Liu: Shenzhen University
Chunfang Hu: Shenzhen University
Junbiao Li: Shenzhen University
Hailong Liao: Shenzhen University
Minhua Shao: Clear Water Bay
Meng Ni: The Hong Kong Polytechnic University
Bin Chen: Shenzhen University
Zongping Shao: Curtin University
Heping Xie: Shenzhen University

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract Thermo-mechanics of cathode is closely related to the durability of high-temperature solid oxide fuel cells (SOFCs), with two main mechanical failures during thermal cycling: interface delamination and bulk cracking of cathode. Bulk cracking, caused by insufficient fracture strength/stiffness is a big concern but often overlooked. Here, we introduce chemical hydration to offset the thermal expansion, enhancing the cathodic mechanical stiffness and fracture strength, thus promoting the thermo-mechanical durability of cathode in proton ceramic fuel cells (PCFCs). Such chemical-induced expansion offset is achieved by strengthening intergranular bonding inside the bulk cathode after the hydration, preventing granule detachment during thermal shrinkage. As a demonstration, the stiffness-enhanced air electrode (BaCo0.7Ce0.15Y0.15O3, noted as s-BCC-Y) exhibits 86% enhancement of fracture strength, thus thermal cycling stability with almost no degradation after 35 harsh thermal cycles between 600 and 300 °C, surpassing pristine BaCo0.7Ce0.3O3 and many cobalt-free PCFC cathodes. Benefitted from the improved stiffness of cathode, full cell with the s-BCC-Y electrode demonstrates enhanced power output. This work highlights the importance of bulk cathode thermo-mechanics in developing robust SOFCs for high temperature energy applications.

Date: 2025
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DOI: 10.1038/s41467-025-57611-1

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