High-power density monolithic fuel cell stack

Abstract The transportation sector is currently undergoing a technology shift from internal combustion engines to electric motors powered by batteries. However, their limited range and long charging times limit wide-spread adoption. Electrified transportation powered by solid oxide fuel cells (SOFCs) offer an attractive alternative especially for heavy freight and long-range transportation, as this technology can provide high-efficiency and flexible fuel choices. Thus far, the technology is mostly used for stationary applications owing to the high operating temperature, low volumetric and gravimetric power density, and poor robustness towards thermal cycling and mechanical vibrations of conventional ceramic-based cells. Here, we present a novel metal-based monolithic fuel cell design to overcome these issues. Highly cost-competitive and scalable manufacturing methods are employed for fabrication, and only a single heat treatment is required, as opposed to two or three for conventional SOFCs. The design is further optimised through three-dimensional multiphysics modelling, nanoparticle infiltration, and corrosion-mitigating treatments. The monolithic fuel cell shows exceptionally high power density (5.6 kW/L) revealing the vast potential of SOFC technology for transport applications.