SOFC Protection Coatings Based on a Cost-Effective Aluminization Process Email Page
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Performer:  NexTech Materials Ltd. Location:  Lewis Center, Ohio
Project Duration:  06/28/2012 – 12/31/2017 Award Number:  SC0008203
Technology Area:  Solid Oxide Fuel Cells Total Award Value:  $1,991,406
Key Technology:  Core Technology DOE Share:  $1,991,406
Performer Share:  $0

Appearance of coated and uncoated 304 austenitic<br/>stainless steel after (a) 500 hours in an oxidizing<br/>atmosphere at 900°C; and (b) 24 hours in<br/>a coking atmosphere at 600°C.
Appearance of coated and uncoated 304 austenitic
stainless steel after (a) 500 hours in an oxidizing
atmosphere at 900°C; and (b) 24 hours in
a coking atmosphere at 600°C.

Project Description

NexTech Materials will demonstrate the applicability of their aluminization process to solid oxide fuel cell (SOFC) applications. Two commercially important systems will be investigated: (1) Compatibility of aluminide coating with SOFC stack components will be evaluated, including interactions with sealant materials and other cell components. A complete interconnect coating solution will be demonstrated by integrating the aluminide coating with the existing manganese cobalt oxide (MCO) active layer coating. The performance of these dual MCO/aluminide coated interconnects will be validated through three-cell stack tests. (2) The high-temperature corrosion protection and chromium volatilization mitigation of aluminide coated balance-of-plant (BOP) components will also be evaluated. The commercial potential of the aluminization process for providing protective aluminide coatings for both the non-active seal area of metallic interconnects and BOP components will be quantified based on an analysis of cost and performance. This work leverages NexTech’s process technology for applying conductive oxide protective coatings to ferritic steels and has already been translated from the laboratory to pilot-scale manufacturing.

Project Benefits

NexTech Materials builds upon encouraging preliminary results to develop a commercially viable aluminization process that is amenable to high volume SOFC manufacturing. This work will leverage NexTech’s commercial process technology for applying conductive oxide protective coatings to ferritic steels – a process that has already been translated from the laboratory to pilot scale manufacturing at NexTech. It is anticipated that this will expedite commercialization of the aluminization process.

Presentations, Papers, and Publications

Contact Information

Federal Project Manager Seth Lawson: seth.lawson@netl.doe.gov
Technology Manager Shailesh Vora: shailesh.vora@netl.doe.gov
Principal Investigator Neil Kidner: n.kidner@nextechmaterials.com