Abstract
In this work, a dense YSZ coating with homogenous structure was produced by atmospheric plasma spraying (APS) on a NiO-YSZ anode supported by a porous metal substrate. A powder separator was used to limit fluctuations in the particle stream, thus stabilizing the process. During feeding, the YSZ powder was separated into fine particles that were fed directly to the plasma and coarse particles that were collected and reused. The coatings obtained exhibited high homogeneity both across the surface and through the thickness. SEM images showed that the YSZ layer was crack-free and that its porosity ratio rivaled that of vacuum plasma sprayed zirconia when two separators were used. Based on these observations and the results of gas leak rate measurements, the potential of online powder separation to improve SOFC electrolyte performance has been established.
