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This quarterly progress report was prepared under field work proposal (FWP) 40552 and covers technical work performed during the period October 1 through December 31, 2013 (FY14 1st quarter). The report highlights and documents technical progress and milestone status in tasks related to advanced cell and stack component materials development and computational design and simulation. Technical highlights related to cell and stack materials development and characterization include: • Surface modified, Ce-modified MC spinel-coated AISI 441 exhibited improved spallation resistance (compared to coated mill reference 441) after 30,000 hours of oxidation at 800ºC in air. Similar beneficial results from surface modification were observed after 26,000 hours of oxidation at 850ºC. • MnCo spinel coatings prepared from metallic powder precursors exhibited low area-specific resistance after 12,000 hours of testing at 800°C. • Long-term validation tests (6,000 hours of operation followed by 10 deep thermal cycles) of surface-blasted, spinel-coated AISI 441 interconnects were completed using PNNL’s SECA CTP stack test fixture. Results of post-test results will be reported in the next quarterly progress report. • Long-term evaluation of compliant glass seals (SCN-1 glass with YSZ fibers) was in progress using PNNL’s SECA CTP stack test fixture. • Baseline testing of LSCF-based cells from Fuel Cell Materials was performed in PNNL’s SECA CTP stack test fixture. Overall performance was similar to that previously obtained with similar cells from H.C. Starck. • A study on pore coarsening of compliant glass seals with and without inert fillers (ZrO2 short fibers or ZrO2 crushed hollow balls) has reached 2,000 hours of testing; results to date indicate that the addition of the fillers was partially effective in hindering the pore coalescence process. • Cell tests attempting to correlate effects of fuel water content on anode performance with previously observed changes in Ni/YSZ anode microstructure were initiated. Technical highlights in the computational modeling area include: • A method to interface the 3D SOFC-MP modeling tool with commercial FEA codes ABAQUS and ANSYS was developed to facilitate model construction and output of the predicted temperature field for structural stress analyses of stacks. • The error estimation and verification tools of the reduced order modeling (ROM) framework was improved to facilitate error handling for a large number of cases and perform user-specified test cases for error analysis of the generated ROM. • Mechanical behavior and damage characteristics of the compliant glass seal was investigated for a large planar cell design under different realistic electrochemical operating conditions (as predicted using SOFC-MP 3D) and thermal cycling events. • The methodology for lifetime prediction of the interconnect was improved to include the mechanical influence of the spinel protection coating on the prediction of critical scale thickness. 3 • Experimental characterization of the crack healing rate was performed for compliant glass SCN-1 with various amounts of fiber reinforcement. This information is needed for modeling evaluations of compliant seal healing during stack operations

FY14 Q1 Progress Report for SECA Core Technology Program