Synthesis of metal and ceramic composite particles for fuel cell electrodes

Metal and ceramic (CoO/Ni and MgFe2O4/Ni) composite particles for molten carbonate fuel cell (MCFC) cathodes were prepared from filament shaped Ni particles by a mechanical coating technique using a new vessel type mixer named the Theta composer. The morphology of the composite particles consisted of a Ni grain coated with fine ceramic particles without changing the filament structure. Moreover, a CoO/NiO composite cathode and a MgFe2O4/NiO composite cathode were successfully fabricated from the composite particles by a doctor blade tape casting method. The composite cathode had good porous structure with high porosity. It suggests that the composite cathode can be applied as practical large area cathodes. Ni solubility of the CoO/NiO composite cathode and MgFe2O4/NiO composite cathode into a (Li0.52Na0.48)2CO3 melt at 650 °C in 10%CO2–7%O2–83%N2 at 1.2 MPa were about half and one-quarter of that of NiO, respectively. Therefore, the composite cathode is a promising candidate for a new cathode of MCFCs because of its high stability in molten carbonate and good porous structure.