Coatings for SOFC metallic interconnects

Patent metadata

Field	Value
Publication number	US-9452475-B2
Application number	US-201313781206-A
Country	US
Kind code	B2
Filing date	Feb 28, 2013
Priority date	Mar 1, 2012
Publication date	Sep 27, 2016
Grant date	Sep 27, 2016

Abstract

Various methods of treating a chromium iron interconnect for a solid oxide fuel cell stack and coating the interconnect with a ceramic layer are provided.

First claim

What is claimed is:

1. A method of making an interconnect for a solid oxide fuel cell stack, comprising:
providing first metallic powder particles comprising Cr and Fe in a mold cavity;
providing second powder particles comprising one or more of Sr, La, Mn and Co oxides in the mold cavity;
compacting the first and second powder particles in the same compacting step to form the interconnect; and
coating at least one surface of the interconnect with a protective coating after the step of compacting.

2. The method of claim 1 , wherein the first and second powder particles are mixed together to form a powder mixture prior to being provided to the mold cavity as the powder mixture.

3. The method of claim 2 , further comprising adding a lubricant to the powder mixture prior to the step of compacting.

4. The method of claim 3 , wherein the interconnect has at least one of Sr, La, Mn and Co oxide regions throughout its thickness.

5. The method of claim 1 , wherein the first powder particles are provided in the mold cavity first and the second powder particles provided on top of the first powder particles in the mold cavity and wherein the compacting results in lanthanum strontium manganate (LSM) or manganese cobalt oxide (MCO) regions on a top surface of a Cr—Fe alloy interconnect.

6. The method of claim 1 , wherein the second powder particles are provided in the mold cavity first and the first powder particles provided on top of the second powder particles in the mold cavity and wherein the compacting results in lanthanum strontium manganate (LSM) or manganese cobalt oxide (MCO) regions on a bottom surface of a Cr—Fe alloy interconnect.

7. The method of claim 1 , wherein:
the first powder particles are provided to the mold first and the second powder particles are electrostatically attracted to a bottom surface of a punch used to compact the powder particles; and
the punch presses the second powder onto the first powder to compact the first and the second power particles to form a Cr—Fe alloy interconnect with lanthanum strontium manganate (LSM) or manganese cobalt oxide (MCO) regions on a top surface of the interconnect.

8. The method of claim 1 , wherein a surface area of the interconnect is increased relative to an interconnect made only by compacting the first powder particles in the same mold cavity.

9. The method of claim 1 , wherein the first powder particles comprise a mixture of elemental Cr and elemental Fe particles or Cr—Fe alloy powder particles.

10. The method of claim 1 , wherein the second powder particles comprise lanthanum strontium manganate (LSM) or manganese cobalt oxide (MCO) powder particles.

11. The method of claim 1 , wherein the first and second powder particles are compacted to form the interconnect having one or more of Sr, La, Mn and Co oxide regions on at least a first surface of the interconnect, and the protective coating is formed on at least the first surface of the interconnect.

12. The method of claim 1 , wherein the second powder particles form depth penetrations of the protective coating into the interior of the interconnect.

13. The method of claim 1 , further comprising sintering the interconnect after the step of compacting and before the step of coating.

Assignees

• Bloom Energy Corp

Inventors

• Armstrong Tad
• Wilson James
• Herchen Harald
• Darga Daniel
• Pillai Manoj

Classifications

• H01M8/0208

  Alloys · CPC title

• B22F7/04

  with one or more layers not made from powder, e.g. made from solid metal · CPC title

• C22C27/06

  Alloys based on chromium · CPC title

• C23C24/082

  without intermediate formation of a liquid in the layer · CPC title

• B22F7/02 Primary

  of composite layers {(B22F7/002 takes precedence)} · CPC title