Atmosphere plasma spray and robot digital fabricating were integrated and presented to prepare the planar PEN and MOLB-type PEN SOFCs. On the basis of the spraying conditions optimized previously and the self-developed functionally graded powder feed system, two kinds of PEN cells were prepared. Then the microstructure and material components of the PEN cells were analyzed. The results show that graded layers were formed between the electrodes and electrolyte. Moreover, the material components and the porosity of the graded layers vary gradually. In particular, the porosities of the anode and cathode reach 32.74%, 32.24%, respectively. Using the AC complex impedance technology, the conductivity of the MOLB-type composite electrode is tested. As a comparison, the electrical conductivity of the MOLB-type composite electrode with the graded layers is larger than that without the graded layers.

A numerical model is developed to study the effects of the contact resistance, droplet impacting droplet temperature, and substrate temperature on the droplet solidification rate and temperature of the droplet under the condition when the substrate can melt and re-solidify. Two-dimensional simulations show that the interface velocity is small in the area of poor contact with an irregular solidification interface shape. During the impact of Molybdenum on a steel substrate, Mo solidifies while the steel substrate melts.