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Development of plasma-sprayed molybdenum carbide-based anode layers with various metal oxides for SOFC.

Faisal, N.H.; Ahmed, R.; Katikaneni, S.P.; Souentie, S.; Goosen, M.F.A.


R. Ahmed

S.P. Katikaneni

S. Souentie

M.F.A. Goosen


Air plasma-sprayed (APS) coatings provide an ability to deposit a range of novel fuel cell materials at competitive costs. This work develops three separate types of composite anodes (Mo-Mo2C/Al2O3, Mo-Mo2C/ZrO2, Mo-Mo2C/TiO2) using a combination of APS process parameters on Hastelloy®X for application in intermediate temperature proton-conducting solid oxide fuel cells. Commercially available carbide of molybdenum powder catalyst (Mo-Mo2C) and three metal oxides (Al2O3, ZrO2, TiO2) was used to prepare three separate composite feedstock powders to fabricate three different anodes. Each of the modified composition anode feedstock powders included a stoichiometric weight ratio of 0.8:0.2. The coatings were characterized by scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, nanoindentation, and conductivity. We report herein that three optimized anode layers of thicknesses between 200 and 300µm and porosity as high as 20% for Mo-Mo2C/Al2O3 (250-µm thick) and Mo-Mo2C/TiO2 (300µm thick) and 17% for Mo-Mo2C/ZrO2 (220-µm thick), controllable by a selection of the APS process parameters with no addition of sacrificial pore-forming material. The nanohardness results indicate the upper layers of the coatings have higher values than the subsurface layers in coatings with some effect of the deposition on the substrate. Mo-Mo2C/ZrO2 shows high electrical conductivity.


FAISAL, N.H., AHMED, R., KATIKANENI, S.P., SOUENTIE, S. and GOOSEN, M.F.A. 2015. Development of plasma-sprayed molybdenum carbide-based anode layers with various metal oxides for SOFC. Journal of thermal spray technology [online], 24(8), pages 1415-1428. Available from:

Journal Article Type Article
Acceptance Date Aug 13, 2015
Online Publication Date Sep 25, 2015
Publication Date Dec 31, 2015
Deposit Date May 26, 2016
Publicly Available Date Sep 26, 2016
Journal Journal of thermal spray technology
Print ISSN 1059-9630
Electronic ISSN 1544-1016
Publisher Springer
Peer Reviewed Peer Reviewed
Volume 24
Issue 8
Pages 1415-1428
Keywords Air plasma spray; Anode; Molybdenum carbide; SOFC
Public URL


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