Effect of Low Plasma Spraying Power on Anode Microstructure and Performance for Metal-Supported Solid Oxide Fuel Cells

Metal-supported solid oxide fuel cells have broad application prospects in distributed power generation, transportation, military, and other fields. The electrochemical performance of the cell is still a challenge in commercial applications. Regulating the anode microstructure and optimizing polarization characteristics are effective methods. In this study, atmospheric plasma spraying technology is chosen to prepare the Ni-Gd_0.2Ce_0.8O_1.9(GDC) anodes using different low plasma powers (18, 21, 24 kW), which is cost-effective and efficient. The power effect on anode microstructure and electrochemical performance is investigated. The results show that as the plasma power decreases from 24 to 18 kW, the anode’s gas permeability and three-phase reaction boundary (TPB) gradually increase. Reducing the spraying power can decrease polarization resistance and improve power density. The 18-kW anode exhibits the lowest polarization resistance and the best output performance. Open-circuit voltage and maximum power density are 1.03 V and 0.89 W cm⁻² at 750 °C, respectively. The polarization resistance and total resistance are 0.19 and 0.40 Ω cm², respectively. The experimental results prove that atmospheric plasma spraying can realize the rapid and low-cost anode preparation for high-performance MS-SOFC.