Nanocrystalline zirconia ceramics and films prepared by chemical vapor synthesis and deposition

We have prepared thin yttria-stabilized zirconia (YSZ) electrolyte layers by chemical vapor deposition (CVD) on a pre-sintered NiO/YSZ fuel cell anode substrate. Structural analysis by scanning electron microscopy (SEM) and x-ray-diffraction shows a homogeneous, nanocrystalline layer. Conventional electrolyte films reach desired electrical properties only at elevated temperatures, typically 1000°C to 1100°C. The YSZ films grown by CVD on rough anode substrates show better growth behavior and less defects at the anode/electrolyte interface than films deposited by conventional methods (screen printing, sol-gel). Results of electrical properties at lower SOFC working temperatures are obtained by impedance spectroscopy on pressed nanocrystalline YSZ powder pellets produced by chemical vapor synthesis (CVS).