Development of High-Chromium Porous Steels for Metal-Supported Solid Oxide Electrolysis Cells

Metal-supported solid oxide electrolysis cells (MS-SOECs) constitute a promising technology for high-temperature (500-900°C) hydrogen production owing to low cost and robustness, especially in contrast to electrolyte and electrode supports. Ferritic stainless steel (FSS) is selected for the supports because its thermal expansion coefficient is similar to that of the electrolyte, thereby improving cell compatibility. However, durability is limited by the corrosion of the metal support in both oxidizing and reducing environments, as well as the cracking and delamination of brittle layers. Additionally, the diffusion of iron, chromium, and nickel between the metal support and the cathode can alter material properties. These issues mainly stem from microstructural changes and mechanical stresses caused by repeated heating and cooling cycles over time. The research aims at developing oxidation-resistant, high-chromium porous and dense alloys with strong mechanical properties at high temperatures, using powder metallurgy or 3D printing techniques. The design is guided by previously established material selection and performance indices for the metal support and for the entire cell. The novel steel supports and commercial steel supports are subjected to high temperature in different atmospheres. The mechanical, chemical and structural properties of the produced samples and the corroded samples are determined and compared to one another.