Effect of Elastic Network of Ceramic Fillers on Thermal Cycle Stability of a Solid Oxide Fuel Cell Stack

Glass‐based seals for planar solid‐oxide fuel‐cell (SOFC) stacks are open to uncontrolled deformation and mechanical damages, limiting both sealing integrity and stack reliability, particularly in thermal cycle operations. If the glass‐based seals work like an elastomer‐based compressive seal, SOFC stacks may survive unprecedented numbers of thermal cycles. A novel composite sealing gasket is successfully developed to mimic the unique features of the elastomer‐based compressive seal by controlling the composition and packing behavior of binary ceramic fillers. A single‐cell SOFC stack undergoes more than 100 thermal cycles with little performance loss, during which the sealing integrity is lost/recovered repeatedly upon cooling and reheating, corresponding to unloading/loading of the elastomer‐based compressive seal. The thermal‐cycle responses of the SOFC stack are explained in sequence by the concurrent events of elastic deformation/recovery of ceramic filler network and corresponding redistribution of sealing glass.