Ceramic AM monolithic SOFC gyroids improve fuel cell efficiency
A research team from the Technical University of Denmark (DTU), Kongens Lyngby, Denmark, led by Prof Vincenzo Esposito of the Department of Energy Conversion and Storage (DTU Energy), has demonstrated a novel architectural approach to SOFC design. The work is intended to support efforts to improve fuel cell efficiency for transport applications.
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The project was carried out in collaboration with researchers from DTU Construct, with Associate Professor Venkata Karthik Nadimpalli contributing expertise in mechanical behaviour and the structural optimisation of architected ceramic materials. The collaboration helped assess the structural stability of the thin-walled gyroid architecture under thermal and operational conditions.
Defining the power-to-weight ratio as the key parameter for SOFCs to improve performance and range of hydrogen-powered transportation to the next level, the team developed monolithic SOFCs with nature-inspired, thin-walled gyroid geometries made from yttria-stabilised zirconia (8YSZ) and manufactured on the recently acquired Lithoz CeraFab ceramic Additive Manufacturing machine.
At the device level, the architecture demonstrates power-to-weight ratios around 1 W g⁻¹, compared to around 0.2 W g⁻¹ for conventional planar SOFC architectures. “This innovation is a real paradigm shift from planar stacking to monolithic architectures,” Prof Esposito explained.
This departure from stacking planar items could reportedly significantly affect the search for further power-density potentials in hydrogen propulsion, as the combination of thin inner walls with the elimination of interconnects and sealants results in significant weight, thermal mismatch and mechanical stress reduction, while improving the utilisation of the available volume. The team states that the compact, lightweight SOFCs created could enable new design approaches of both long-range and ultra-compact hydrogen engine designs for transportation on water, on land, and particularly in the air.
Prof Esposito shared, “Our motto, ‘Escaping Flatland,’ sounds like a logical step, but it has long been impossible to achieve. The particular arrangement of materials and microstructures requires a significantly elevated level of complexity – but until recently, we simply lacked the tool to make this concept a reality. 8YSZ remains one of the most widely used and technologically mature electrolyte materials for SOFCs. With its mature precision and scalability, Lithoz LCM technology has demonstrated the highest repeatability for these bio-inspired TPMS geometries with the thinnest possible inner walls, which inherently meet the gas supply requirements. The monolithic concept could only be achieved by precisely replicating those gyroid units and adding a sealed shell frame to maintain gastight conditions.”
Johannes Homa, Lithoz CEO added, “By realising 8YSZ monolithic fuel cells with intricate gyroid geometries on their Lithoz CeraFab printer, DTU was able to reduce the dependence on conventional interconnect and sealing architectures inherent to stacked flat items. These elements have traditionally been the Achilles heel in the search for better power density in commercial planar SOFC stacks and, therefore, the traditional focus of attention in the quest for a more advantageous power-to-weight ratio. With their revolutionary monolithic concept, these elements eliminate the need to gradually optimise exit points, paving the way for a complete rethinking of fuel cell design. Of course, we are extremely excited about the impact this will have on the worldwide hydrogen-based industry.”
As the design and test phase at DTU Energy has now concluded, the team around Professor Esposito plans to scale up the project for industrial application.
