Ultrathin anode-supported YSZ electrolyte membranes fabricated by dip-coating combined with ultraviolet curing

Authors:
  • HXHao Xiong
    Hao Xiong
  • HLHaodong Li
    Haodong Li
  • ZJZhihao Jin
    Zhihao Jin
  • YYYan Yue
    Yan Yue
  • CZChuan Zhou
    Chuan Zhou
  • WCWanqing Chen
    Wanqing Chen
  • GYGuangming Yang
    Guangming Yang
  • MQMinghui Qiu
    Minghui Qiu
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Abstract
Ultrathin yttria-stabilized zirconia (YSZ) electrolyte membranes are critical for reducing ohmic resistance and enabling intermediate-temperature operation of solid oxide fuel cells (SOFCs). However, the fabrication of gas-tight electrolytes with micrometer-scale thickness on porous anode supports remains challenging due to capillary infiltration and structural instability during liquid-membrane formation. Herein, a UV-curing-assisted dip-coating strategy is proposed to fundamentally regulate the formation and stabilization of ultrathin YSZ electrolyte membranes. By employing a resin-based ceramic slurry with tailored rheological properties and low surface tension, capillary penetration into porous anode substrates is effectively suppressed, enabling the formation of uniform and continuous liquid membranes. Subsequent ultraviolet curing induces rapid cross-linking of the resin matrix, generating a transient supporting skeleton that stabilizes the green membrane and prevents particle migration and collapse. Through optimization of slurry solid content and sintering protocols guided by thermal decomposition behavior, dense and defect-free YSZ electrolyte membranes with a minimum thickness of approximately 2 μm are successfully fabricated. Single cells assembled with the ultrathin electrolytes deliver peak power densities of 750 mW cm−2 at 800 °C and 150 mW cm−2 at 650 °C, demonstrating excellent gas tightness and stable electrochemical performance. This scalable and low-cost UV-curing-assisted dip-coating approach provides a versatile pathway for the controlled fabrication of ultrathin oxide electrolyte membranes on porous supports, with broad applicability to intermediate-temperature SOFCs and related electrochemical devices.

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