Papers Abstract

Novel Fabrication of Porous Ni-5 wt.% Al Alloy Electrode Below the Melting Point of Aluminum
An in-situ sintered Ni-5 wt.% Al alloy anode for high-temperature fuel cells (HTFCs) was fabricated successfully using a green sheet consisting of a physical mixture of inexpensive Ni and Al elemental powders at reduced temperatures. Two processes—the formation of Ni–Al alloy via the AlCl3 activator under flowing hydrogen gas and the sintering of Ni–Al—occurred at the same time during pretreatment for cell operation. The AlCl3 activator reduced the synthesis reaction temperature and sintering temperature of Ni–Al alloy to nearly 600 C. A twophase alloy of a Ni3Al intermetallic compound and a Ni–Al solid solution was obtained after sintering at 600 C. The creep resistance of the in-situ sintered Ni-5 wt.% Al alloy was better than that of the conventional Ni–Al alloy green sheet, even though the sintering temperature of the Ni-5 wt.% Al alloy was 600 C. This novel preparation method for Ni–Al alloys can greatly reduce the cost of anode fabrication for HTFCs and in turn accelerate the commercialization of HTFCs.