Advanced Materials and Manufacturing Processes for MW-Scale SOFC Power Systems for Improved Stack Reliability, Durability and Cost


LG Fuel Cell Systems, Inc.
Website:  LG Fuel Cell Systems Inc.
Award Number:  FE0026098
Project Duration:  10/01/2015 – 12/31/2018
Total Award Value:  $3,125,150
DOE Share:  $2,500,000
Performer Share:  $625,150
Technology Area:  Solid Oxide Fuel Cells
Key Technology:  Core Technology
Location:  North Canton, Ohio

Project Description

LG Fuel Cell Systems Inc. (LGFCS) will team with Carpenter Technology Corporation (Carpenter) to qualify a material and advanced manufacturing process solution for selected metallic components of an advanced integrated stack block that is the heart of the LGFCS solid oxide fuel cell (SOFC) system. It is intended that these cost reduced components will also increase the reliability and endurance of the LGFCS cell and stack technology. Specific objectives are to identify and validate a material solution for the "hot metal components" with foresight on how the components will be mass produced, validate the new process solution for making quality parts that will meet product cost targets, and demonstrate that the new material and components do not adversely impact stack performance while operating on natural gas. An integrated material set and processing solution will be developed using powder metals processing which has proven to be an enabling technology capable of delivering net or near net shape components as well as for creating compositions, microstructures, and properties that are otherwise unattainable. Researchers will screen a number of advanced manufacturing processes and select one or more that are most advantageous for producing selected metallic components at commercial volumes. This work will be accomplished through collaboration of metallurgists and processing engineers from Carpenter with product design and cost engineers from LGFCS. The project team will test a full-scale integrated stack block using components from the new material set and processing solution to confirm its readiness for commercial field deployment. This project will build on previous DOE funded work; most recently DE-FE0023337.

Project Benefits

The LGFCS team expects this research to result in an optimized material set and processing solution that enables a net, or near net shape solution for the selected hot metal components. The focus is on reducing component costs for a critical SOFC subsystem and increasing the impact of the material set and its processing on the reliability and endurance of the LGFCS cell and stack technology.

Contact Information

Federal Project Manager 
Patcharin Burke:
Technology Manager 
Shailesh Vora:
Principal Investigator 
Charles Osborne :

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