Parameters Optimization for Electrophoretic Deposition of Mn1.5Co1.5O4 on Ferritic Stainless Steel Based on Multi-Physical Simulation

Solid oxide fuel cells (SOFCs) are an effective and sustainable technology for hydrogen utilization. As operating temperatures decrease, metal interconnects and supports are widely employed in SOFCs. It is critical to apply a protective coat on ferritic stainless steel (FSS) to suppress Cr evaporation and element interdiffusion under high temperatures. Electrophoretic deposition (EPD) is a promising approach for depositing metal oxides on FSS substrate. Here, a method based on 3D multi-physical simulation and orthogonal experimental design was proposed to optimize deposition parameters, including applied voltage, deposition time, and electrode distance. The EPD process to deposit Mn1.5Co1.5O4 particles in a suspension of ethanol and isopropanol was simulated and the effects of these three factors on the film thickness and uniformity were analyzed. The results indicate that applied voltage has the greatest impact on deposition thickness, followed by deposition time and electrode distance. Meanwhile, deposition time exhibits a more significant effect on film unevenness than applied voltage. Additionally, the particle-fluid coupling phenomenon was analyzed during the EPD process. In practice, these deposition parameters must be selected appropriately and the deposition time must be controlled to obtain a uniform coating. The proposed method can reduce cost and shorten the design period.