Fabrication of defect free co-sintered electrolytes with thickness between 12 μm and 40μm has been demonstrated on planar and tubular cells produced via a spray coating process. Leak testing using a helium leak method showed low diffusional leak rates for cells using optimized spray parameters. The electrolytes were characterized using scanning electron microscopy to qualitatively assess pin holes. Average open circuit voltages (OCVs) of 1080 mV were obtained on tubular cells with spray-coated electrolytes using 3% humidified hydrogen as the fuel. This paper presents spray coating as a viable, cost effective method for electrolyte application in co-fired, anode supported SOFCs.

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