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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Methods of fabricating porous ceramic electrodes for solid state battery applications

Compositions and methods for the fabrication of electrode and porous lithium-garnet electrolyte scaffolds for use in solid state batteries and other devices are provided. The methods produce porous structures using phase inversion or high shear compaction processes to fabricate a solid-state battery electrode material from LLZO electrolytes. Engineered electrode structures with a porous scaffold of solid electrolyte material provide lower interfacial resistances and a mechanical support for a thin solid electrode layer improving performance.

Tucker, Michael↗
DOE OSTI2020

Dual 3D Ceramic Textile Electrodes: Fast Kinetics for Carbon Oxidation Reaction and Oxygen Reduction Reaction in Direct Carbon Fuel Cells at Reduced Temperatures

Abstract Direct carbon fuel cells (DCFCs) are an efficient energy‐conversion technology capable of generating electricity with carbon‐dioxide‐capture chemistry with solid carbon as fuels. The efficiency and performance of DCFCs depend on the kinetics of the carbon oxidation reactions (COR) and the oxygen reduction reactions (ORR), each occurring at anode and cathode, respectively. The limited active sites paired with reduced temperatures greatly decrease the efficiency of the electrochemical reactions. Ultraporous dual‐3D ceramic textiles (dual‐3DCT) are integrated into electrolyte‐supported DCFCs to enhance charge and mass transfer at the electrodes. Improved COR at the anode is achieved by the synergy between the 3DCT NiO–Ce 0.8 Gd 0.2 O 1.95 (GDC) structure and optimal carbon fuel choice. In a comparative study, DCFCs using graphitic carbon (GC) as fuel show the best COR performance when compared to DCFCs utilizing alternative fuels such as carbon black (CB) and activated carbon (AC). The 3DCT Sm 0.5 Sr 0.5 CoO 3‐δ –GDC (SSC–GDC) composite cathode shows electrochemical performance superior to that of the conventional screen‐printed SSC–GDC. A peak power density of 392 mW cm −2 at 600 °C is obtained in a DCFC using the 3DCT‐anode/electrolyte/3DCT‐cathode configuration, an unprecedented value for any reported DCFC as of yet. This points toward promising applications of dual‐3DCT electrodes for reduced‐temperature DCFCs.

Bian, Wenjuan↗
DOE OSTI2021

Redox-stable symmetrical solid oxide fuel cells with exceptionally high performance enabled by electrode/electrolyte diffuse interface

Here, in this study, we report a high performance and redox-stable symmetrical solid oxide fuel cell (SOFC) based on (Ba 0.5 Sr 0.5 ) (Mo 0.1 Fe 0.9 )O 3-δ (BSMF) electrode and La 0.8 Sr 0.2 Ga 0.8 Mg 0.2 O 3-δ (LSGM) electrolyte. BSMF is able to operate both as anode and cathode. Excellent electrocatalytic activity has been achieved on BSMF towards hydrogen oxidation and oxygen reduction. Due to its closely matched lattice parameter to LSGM electrolyte, a unique diffuse interface is formed between BSMF and LSGM. Compared to a clean interface, e.g. BSMF/gadolinium doped ceria interface, this diffuse interface promotes the performance of BSMF electrode 1–1.8 times in 600–800 °C. Polarization resistance of the BSMF/LSGM specimen is as low as 0.047 and 0.007 Ωcm 2 in humidified H 2 and in air at 800 °C, respectively. On the BSMF/LSGM/BSMF symmetrical cell, a maximum power density of 2.28 W/cm 2 is achieved at 800 °C, the highest among with redox-stable ceramic electrodes to the best of our knowledge. Redox stability of this cell is confirmed. The role of anode and cathode is reversed back and forth in different operation modes. No apparent degradation is observed through 4 cycles within a 110 h operation period. These findings demonstrate that (Ba 0.5 Sr 0.5 ) (M o0.1 Fe 0.9 )O 3-δ coupled with LSGM electrolyte is an excellent choice to build a high performance, redox-stable SOFC.

25 ENERGY STORAGE↗
DOE OSTI2020

Temperature-induced changes in the synthesis gas composition in a high-temperature H 2 O and CO 2 co-electrolysis system

Solid oxide electrolysis cell (SOEC) is an attractive renewable technology capable of producing synthesis gas (H 2 + CO) from H 2 O and CO 2 . An SOEC consists of a solid oxide electrolyte and two ceramic or metal-ceramic electrodes. H 2 O and CO 2 are electrolyzed at the cathode producing H 2 and CO, releasing O 2- ions, which travel through the electrolyte to the anode side and recombine to produce pure oxygen gas as the byproduct. In the present study, a La 0.7 Sr 0.2 Ni 0.2 Fe 0.8 O 3 cathode was used to co-electrolyze H 2 O and CO 2 at three different operating temperatures- 700 °C, 750 °C and 800 °C. Synthesis gas was produced at all three operating temperatures with 100% Faradaic efficiency. The composition of the syngas, however, was found to be a function of the operating temperature. In general, the H 2 /CO ratio in the syngas decreased with increased temperature. This was partially due to CO 2 electrolysis becoming more favorable compared to H 2 O electrolysis at higher temperatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Enhancing surface activity and durability in triple conducting electrode for protonic ceramic electrochemical cells

With the material system operating at lower temperatures, protonic ceramic electrochemical cells (PCECs) can offer high energy efficiency and reliable performance for both power generation and hydrogen production, making them a promising technology for reversible energy cycling. However, PCEC faces technical challenges, particularly regarding electrode activity and durability under high current density operations. To address these challenges, we introduce a nano-architecture oxygen electrode characterized by high porosity and triple conductivity, designed to enhance catalytic activity and interfacial stability through a self-assembly approach, while maintaining scalability. Electrochemical cells incorporating this advanced electrode demonstrate robust performance, achieving a peak power density of 1.50 W cm −2 at 600 °C in fuel cell mode and a current density of 5.04 A cm −2 at 1.60 V in electrolysis mode, with enhanced stability on transient operations and thermal cycles. The underlying mechanisms are closely related to the improved surface activity and mass transfer due to the dual features of the electrode structure. Additionally, the enhanced interfacial bonding between the oxygen electrode and electrolyte contributes to increased durability and thermomechanical integrity. This study underscores the critical importance of optimizing electrode microstructure to achieve a balance between surface activity and durability.

Protonic Ceramic Electrochemical Cells↗
DOE OSTI2025

Nano-Engineered Interfaces in Dual-Layer Electrodes for Protonic Ceramic Cells with Enhanced Stability and Kinetics

Enhancing interfacial stability and charge transfer in protonic ceramic cells (PCCs) remains a critical challenge, as structural degradation and interfacial resistance often compromise durability and efficiency. Here, we report a nanoengineered dual-layer oxygen electrode architecture designed to address these limitations by introducing a fine-grained nanoparticle interfacial contact layer beneath a porous catalytic backbone. The nanoscale powders, through enhanced sintering activity, densify into a robust interfacial layer that promotes strong chemical bonding, uniform adhesion, and continuous ionic/electronic pathways with the BCZYYb electrolyte. This hierarchical architecture mitigates delamination, redistributes mechanical stress, and establishes efficient charge and mass transport channels without relying on corrosive surface treatments. Electrochemical evaluation demonstrates that the dual-layer design markedly reduces interfacial polarization resistance and accelerates electrode kinetics. Compared to the single-layer counterpart, the architecture achieves a peel strength of 44.53 N/cm 2 , a 40% improvement in peak power density (0.96 W cm –2 at 600 °C), and a 130% enhancement in electrolysis current density (4.78 A cm –2 at 1.57 V). Faradaic efficiency remains as high as 88% under high steam concentrations, underscoring minimal charge loss during practical operation. Notably, the electrode retains stability across 450–600 °C and under transient voltage cycling, with impedance spectra confirming suppressed interfacial resistance growth over prolonged use. These results highlight nanoscale interface engineering as a powerful route to enhance both mechanical robustness and electrochemical kinetics in PCCs. The demonstrated scalability and durability of this architecture provide a versatile platform for advancing solid-state electrochemical systems, including reversible fuel cells and high-efficiency hydrogen production technologies.

Faradaic efficiency↗
DOE OSTI2022

Surface Regulating of a Double–Perovskite Electrode for Protonic Ceramic Fuel Cells to Enhance Oxygen Reduction Activity and Contaminants Poisoning Tolerance

Protonic ceramic fuel cells (PCFCs) are one of the most efficient energy conversion devices. However, the performance of current PCFCs is greatly limited by the sluggish oxygen reduction reaction (ORR) kinetics and the fast degradation of cathode due to contaminants poisoning (such as Cr species and steam). In this work, we report a surface regulating of a double perovskite PrBa 0.5 Sr 0.5 Co 1.5 Fe 0.5 O 5+δ (PBSCF) cathode by a Pr 0.9 Fe 0.7 Co 0.3 O 3 (PFC) catalyst coating to enhance the ORR activity and stability. When tested in direct contact with Cr in the air with 3% H 2 O at 650 °C, the polarization resistance (Rp) of the PFC-PBSCF electrode increases from $\approx$0.39 to 0.45 Ω cm 2 after 100 h operation; in contrast, the R p of a PBSCF electrode increases from 0.63 to 0.82 Ω cm 2 . Further, a PCFC with the PFC-PBSCF cathode demonstrates an excellent peak power density ($\approx$1.08 W cm -2 at 650 °C) and significantly enhanced durability (degradation rate of 0.03 % h -1 ), much better than those of the cells with a PBSCF cathode ($\approx$0.75 W cm -2 and degradation rate of 0.12 % h -1 ). Raman spectroscopy and density functional theory calculations indicate that the PFC catalyst coating diminishes the formation of Cr species, such as (Ba 1-x Sr x )CrO 4 , on the cathode surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Critical insights into the steam electrolysis electrode in protonic ceramic cells for hydrogen production

Intermediate-temperature protonic ceramic electrolysis cells (PCECs), which combine the benefits of both lower- and higher-temperature electrolysis, are among the most efficient technologies for the production of green hydrogen. To ensure economic competitiveness and broad adoption, ongoing innovations in cell materials are essential to improve durability and reduce costs. The water oxidation half-reaction at the anode is a key area for improvement as it is a major contributor to performance degradation and efficiency loss in PCECs. Current anode designs, which are largely derived from solid oxide electrolysis cells, fail to address the specific requirements for PCECs under realistic operating conditions. Here, this Perspective highlights the unique challenges faced by PCEC anodes, focusing on the impact of high steam concentrations and the critical role of proton-coupled electron-transfer mechanisms—factors that are absent in solid oxide electrolysis cells. Furthermore, we explore design principles for advancing anodes tailored for PCECs, offering guidance for future research and development in this promising field.

Electrocatalysis↗
DOE OSTI2022

Highly Active and Durable Air Electrodes for Reversible Protonic Ceramic Electrochemical Cells Enabled by an Efficient Bifunctional Catalyst

The commercialization of reversible protonic ceramic electrochemical cells is hindered by the lack of highly active and durable air electrodes exposed to high concentration of steam under operating conditions. We report findings that dramatically enhance the electrocatalytic activity and stability of a conventional (La 0.6 Sr 0.4 ) 0.95 Co 0.2 Fe 0.8 O 3-δ (LSCF) air electrode by a multiphase catalyst coating composed of a conformal Pr 1-x Ba x CoO 3-δ thin film and exsolved BaCoO 3-δ nanoparticles, are reported. At 600 °C, the catalyst coating decreases the polarization resistance of the LSCF air electrode by a factor of 25 (from 1.09 to 0.043 Ω cm 2 ) in air and the degradation rate by two orders of magnitude (from 1.0 × 10 -2 to 1.8 × 10 -4 Ω cm2 h -1 in humidified air with 30 vol% H2O). Further, a single cell with the catalyst-coated LSCF air electrode at 600 °C demonstrates a high peak power density of 1.04 W cm -2 in the fuel cell mode and a high current density of 1.82 A cm -2 at 1.3 V in the electrolysis mode. The significantly enhanced performance of the LSCF air electrode is attributed mainly to the high rate of surface oxygen exchange, fast surface proton diffusion, and the rapid H 2 O and O 2 dissociation on the catalysts.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An Efficient Bifunctional Air Electrode for Reversible Protonic Ceramic Electrochemical Cells

One of the main bottlenecks that limits the performance of reversible protonic ceramic electrochemical cells (R-PCECs) is the sluggish kinetics of the oxygen reduction and evolution reactions (ORR and OER). Here, the significantly enhanced ORR and OER kinetics and stability of a conventional La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF) air electrode by an efficient catalyst coating of barium cobaltite (BCO) is reported. The polarization resistance of a BCO-coated LSCF air electrode at 600 oC is 0.16 Ω cm 2 , about 30% of that of the bare LSCF air electrode under the same conditions. Further, a R-PCEC with the BCO-coated LSCF air electrode shows exceptional performance in both fuel cell (maximum power density of 1.16 W cm -2 at 600 ºC) and electrolysis (current density of 1.80 A cm -2 at 600 ºC at 1.3 V) modes. Finally, the performance enhancement is attributed mainly to the facilitated rate of oxygen surface exchange.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Electronic Structural Optimization of the Air Electrodes for Reversible Protonic Ceramic Electrochemical Cells via IIIA Cation Doping

Reversible protonic ceramic electrochemical cells (R-PCECs) have emerged as a novel technology for clean and efficient energy generation and storage. Improving the oxygen and proton conduction characteristics and stability of air electrodes at intermediate temperatures is crucial for achieving a high performance. Herein, we optimize the electronic structure of a state-of-the-art PrBa 0.8 Ca 0.2 Co 2 O 5+δ (PBCC) air electrode via doping IIIA cations (Al 3+ , Ga 3+ , and In 3+ ). Also, it is shown that PrBa 0.8 Ca 0.2 Co 1.9 Ga 0.10 O 5+δ (PBCCGa 0.10 ) exhibits improved oxygen reaction activity and hydration capability. Density functional theory calculations confirm that Ga doping provides the most favorable electronic structure. An R-PCEC with PBCCGa 0.10 achieves a peak power density of 2.21 W cm -2 and a current density of −4.64 A cm -2 at 1.3 V at 650 °C. Additionally, the PBCCGa 0.10 electrode performs good operational stability in FC mode (for about 100 h), EC mode (for about 100 h), and reversible cyclic testing (over 200 h) at 600 °C.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

An Active and Robust Air Electrode for Reversible Protonic Ceramic Electrochemical Cells

Reversible protonic ceramic electrochemical cells (RPCECs) are a promising option for efficient and low-cost generation of electricity and hydrogen. Commercialization of R-PCECs, however, hinges on the development of highly active and robust air electrodes. Here, we report an air electrode consisting of PrBa 0.8 Ca 0.2 Co 2 O 5+δ and in situ exsolved BaCoO 3–δ nanoparticles (PBCC–BCO) that shows minimal polarization resistance (~0.24 Ω cm 2 at 600 °C) and high stability when exposed to humidified air with 3–50% H 2 O. An R-PCEC utilizing PBCC-BCO demonstrates remarkable performances at 600 °C: achieving a peak power density of 1.06 W cm –2 in the fuel cell mode and a current density of 1.51 A cm –2 at 1.3 V in an electrolysis mode. More importantly, the RPCECs demonstrate an exceptionally high durability over 1833 h of continuous operation in the electrolysis mode. Furthermore, this work offers an efficient approach to design of high-performance and durable electrodes for R-PCECs.

25 ENERGY STORAGE↗
DOE OSTI2022

Surface restructuring of a perovskite-type air electrode for reversible protonic ceramic electrochemical cells

Reversible protonic ceramic electrochemical cells (R-PCECs) are ideally suited for efficient energy storage and conversion; however, one of the limiting factors to high performance is the poor stability and insufficient electrocatalytic activity for oxygen reduction and evolution of the air electrode exposed to the high concentration of steam. Here we report our findings in enhancing the electrochemical activity and durability of a perovskite-type air electrode, Ba 0.9 Co 0.7 Fe 0.2 Nb 0.1 O 3-δ (BCFN), via a water-promoted surface restructuring process. Under properly-controlled operating conditions, the BCFN electrode is naturally restructured to an Nb-rich BCFN electrode covered with Nb-deficient BCFN nanoparticles. When used as the air electrode for a fuel-electrode-supported R-PCEC, good performances are demonstrated at 650 °C, achieving a peak power density of 1.70 W cm –2 in the fuel cell mode and a current density of 2.8 A cm –2 at 1.3 V in the electrolysis mode while maintaining reasonable Faradaic efficiencies and promising durability.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Novel High Temperature Carbide and Boride Ceramics for Direct Power Extraction Electrode Applications. Final report

The current project aims to develop new carbide and boride ceramic materials that incorporate different metal elements (e.g., (Hf 1-x Zr x )B 2 , also called ceramic solid solutions) and understand the fundamental composition-processing-structure-property relationships for such materials. Specifically, nano powders and related nano-composites for selected mixed metal carbide and boride materials are synthesized from nano-scale mixed precursors obtained from solution-based processing via heat treatment in inert atmosphere. The obtained fine powders were then consolidated into dense ceramics via a novel flash sintering process. The mechanical properties and thermal oxidation resistance for the obtained materials were evaluated for these materials. It was found that different synthesis routes produced powders with somewhat different characteristics in terms of composition and microstructure, which then led to different properties for the final ceramics. The synthesis and processing methods demonstrated in this study might be adopted for developing other similar high temperature ceramics, while the mixed metal or solid solution ceramic materials obtained from this study might be used as hot electrodes for direction power extraction and other energy-related applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

An alternative electrode design for accurate spectral induced polarization measurements in variably saturated porous media

SUMMARY Applications of spectral induced polarization (SIP) require electrodes that maintain hydrologic contact with surrounding soils to capture small electrical responses, often observed as phase shifts in milliradians. For unsaturated soils, electrodes must overcome increased electrical contact impedance due to reduced pore fluid. Traditional designs use a ceramic membrane electrode (CME) with a water reservoir and metal conductor, requiring periodic maintenance to retain electrolytic solution. For field applications where maintenance is impractical, alternative designs are needed. This study evaluated a new electrode design (silica flour electrode, SFE) alongside a CME. SFEs use packed silica flour to store water via capillary forces against a metal conductor. This study examined both designs in three variably saturated soils at soil suctions up to 700 mbar and soil water contents below 1 percent, with SIP measurements across 0.01 to 10 000 Hz frequencies. SFEs match CMEs at high frequencies and perform better at lower frequencies, without requiring ongoing maintenance, making them ideal for field use. In water-only experiments, CMEs produced errors and high noise below 1.5 Hz, whereas SFEs were more accurate. However, CMEs performed better above 300 Hz. In fine sand, SFEs performed better due to the relatively lower contact impedance as compared to CMEs. Both electrode types performed comparably in silty sand and silt loam soils, although CMEs required ongoing maintenance, suggesting potential for long-term reliability issues.

58 GEOSCIENCES↗
DOE OSTI2020

Self-sustainable protonic ceramic electrochemical cells using a triple conducting electrode for hydrogen and power production

The protonic ceramic electrochemical cell (PCEC) is an emerging and attractive technology that converts energy between power and hydrogen using solid oxide proton conductors at intermediate temperatures. To achieve efficient electrochemical hydrogen and power production with stable operation, highly robust and durable electrodes are urgently desired to facilitate water oxidation and oxygen reduction reactions, which are the critical steps for both electrolysis and fuel cell operation, especially at reduced temperatures. In this study, a triple conducting oxide of PrNi 0.5 Co 0.5 O 3-δ perovskite is developed as an oxygen electrode, presenting superior electrochemical performance at 400-600°C. More importantly, the self-sustainable and reversible operation is successfully demonstrated by converting the generated hydrogen in electrolysis mode to electricity without any hydrogen addition. The excellent electrocatalytic activity is attributed to the considerable proton conduction, as confirmed by hydrogen permeation experiment, remarkable hydration behavior and computations.

08 HYDROGEN↗
DOE OSTI2022

An Unbalanced Battle in Excellence: Revealing Effect of Ni/Co Occupancy on Water Splitting and Oxygen Reduction Reactions in Triple–Conducting Oxides for Protonic Ceramic Electrochemical Cells

Porous electrodes that conduct electrons, protons, and oxygen ions with dramatically expanded catalytic active sites can replace conventional electrodes with sluggish kinetics in protonic ceramic electrochemical cells. In this work, a strategy is utilized to promote triple conduction by facilitating proton conduction in praseodymium cobaltite perovskite through engineering non-equivalent B-site Ni/Co occupancy. Surface infrared spectroscopy is used to study the dehydration behavior, which proves the existence of protons in the perovskite lattice. The proton mobility and proton stability are investigated by hydrogen/deuterium (H/D) isotope exchange and temperature-programmed desorption. It is observed that the increased nickel replacement on the B-site has a positive impact on proton defect stability, catalytic activity, and electrochemical performance. This doping strategy is demonstrated to be a promising pathway to increase catalytic activity toward the oxygen reduction and water splitting reactions. The chosen PrNi 0.7 Co 0.3 O 3–δ oxygen electrode demonstrates excellent full-cell performance with high electrolysis current density of –1.48 A cm –2 at 1.3 V and a peak fuel-cell power density of 0.95 W cm –2 at 600 °C and also enables lower-temperature operations down to 350 °C, and superior long-term durability.

08 HYDROGEN↗
DOE OSTI2024

Phase segregation of a composite air electrode unlocks the high performance of reversible protonic ceramic electrochemical cells

One breakthrough in developing highly efficient air electrodes for reversible protonic ceramic electrochemical cells (R-PCECs) is optimizing the sluggish oxygen reduction and water oxidation reactions. Here, we present a novel composite material with a nominal formula of high-entropy Ce 0.2 Ba 0.2 Sr 0.2 La 0.2 Ca 0.2 CoO 3–δ (CBSLCC) that spontaneously self-assembles to three-phase electrocatalysts composed of deficient Ce 0.2–y Ba 0.2 Sr 0.2–x La 0.2–x Ca 0.2 CoO 3–δ (CD-CBSLCC), CeO 2 , and La 0.5 Sr 0.5 CoO 3–δ (LSC). Mechanistic studies corroborate that oxygen reduction may occur on entire air electrode surfaces, followed by water formation preferentially at or near CD-CBSLCC. The CeO 2 phase could provide or consume protons to facilitate the oxygen evolution/reduction kinetics in R-PCECs. The developed electrodes demonstrate a record-high electrochemical performance in dual modes of fuel cells and electrolysis cells, delivering a peak power density of 1.66 W cm –2 at 600 °C and a current density of –1.76 A cm –2 at 1.3 V and 600 °C. Finally, excellent operational stabilities of the fuel cell (200 h at 600 °C), electrolysis cell (200 h at 600 °C), and reversible cycling (548 h at 550 °C) provide a promising and reliable step towards realizing the commercialization of R-PCECs.

30 DIRECT ENERGY CONVERSION↗