Realizing a Robust High-Performance Ni-GDC Nanocomposite Anode for SOFCs by Self-Assembly of Reactive Cosputtered Nanolayers

This study reports a fast and scalable route for fabricating efficient and durable SOFCs, leveraging nickel oxide-gadolinium-doped ceria (NiO-GDC) nanocomposites and thin-film electrolytes based on reactive sputtering. The Ni and GdCe targets are first cosputtered to form films with a stack-layered structure of metallic Ni and GDC, followed by sputtering YZr and GdCe targets alternatively to make multilayer electrolytes. By annealing the sputtered anode-electrolyte assembly with the La0.6Sr0.4Co0.2Fe0.8O3−δ cathode in a single step at 1000 °C, full cells feature heterostructure ceramic multilayers; NiO-GDC nanocomposites with heterointerfaces are in situ constructed, while the multilayer electrolytes are fully dense. The electrochemical performance is significantly enhanced by the insertion of the NiO-GDC nanocomposite anode and the optimization of the film configuration, achieving a peak power density of 2.72 W cm–2 at 800 °C. Furthermore, no degradation is observed during the stability test, and the fine porous nanostructure of the Ni-GDC anode is preserved.