High-Temperature Oxidation-Resistant Ceramic Coatings for Metallic Interconnects in Solid Oxide Fuel Cells: Kinetics, Scale Adhesion, and Failure Mechanisms

Document Type : Original Article

Author

Department of Research and Development, UOP, USA

10.22034/jceem.2026.594680.1044
Abstract
Solid oxide fuel cells (SOFCs) represent a transformative energy conversion technology, yet their commercial viability is critically constrained by the high-temperature degradation of metallic interconnects. This comprehensive review systematically examines ceramic protective coatings for ferritic stainless steel interconnects operating at 650–850 °C, focusing on oxidation kinetics, scale adhesion mechanisms, and failure pathways. Manganese-cobalt oxide (MCO) spinel coatings have emerged as the leading candidate, effectively suppressing chromium oxide scale formation and mitigating cathode poisoning through volatile Cr species retention . Recent advances demonstrate that lanthanum-doped MCO coatings inhibit pore formation and maintain Mn/Co stoichiometry during long-term operation, extending protective service life . The oxidation mechanism follows parabolic kinetics, with coated Crofer 22 APU steel achieving an area-specific resistance (ASR) of 13.11 mΩ·cm² compared to 41.45 mΩ·cm² for uncoated steel after 500 hours at 800 °C . Reactive element additions—Ce, La, Y, Tb—modify scale growth and improve adhesion through reactive element effect mechanisms . Tb-doped CuFe₂O₄ coatings demonstrate reduced oxidation rates and ASR through maintaining a continuous chromia layer that inhibits outward Fe and Cr diffusion . Perovskite-spinel composites incorporating LaNi₀.₆Fe₀.₄O₃-δ exhibit enhanced oxidation resistance compared to pure spinel coatings after 3000-hour exposure . Interfacial shear strength evaluation through four-point bend testing reveals distinct differences between coatings formed with different process parameters . This review concludes that effective SOFC interconnect protection requires integrated coating design combining spinel-perovskite architectures with reactive element doping.

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Articles in Press, Accepted Manuscript
Available Online from 30 July 2026