Is Super-Duplex Stainless Steel Suitable as Metal Support for Solid Oxide Cells?

Abstract

In this study, commercial Ospray-2507 super-duplex stainless steel powder was investigated for the first time as a potential metal support material for solid oxide cells. Initially, metal supports were fabricated and processed in air using various sintering profiles, followed by comprehensive mechanical, structural and electrochemical characterization. The optimal sintering condition was identified as 900 °C for 5 h. Subsequently, sintering under a H2 atmosphere was explored, and its effects on the microstructural and functional properties of the metal supports were systematically to assessed to evaluate the influence of the sintering atmosphere on material performance. Although X-ray diffraction patterns showed no phase changes between the two sintering atmospheres, notable improvements were observed in mechanical, electrochemical, and microstructural properties under H2 sintering. XPS spectra reveal that both air- and hydrogen-treated surfaces remain rich in chromium (Cr) and Manganese (Mn), which together dominate the surface and consequently attenuate the signal from the underlying iron. The thickness of the Cr- and Mn-based oxide layer decreases when sintering MS in H2 atmosphere. Specifically, mechanical strength, as measured by three-point bending tests, increased by a factor of 12.5, and hardness rose from 500.3 to 523.5 HV. Furthermore, electrical conductivity also improved significantly, exhibiting an approximately 2.3–2.4 fold increase under H2-sintered conditions.