Preparation and Electrical Properties of Sr-Doped LaFeO3 Thin-Film Conversion Coatings for Solid Oxide Cell Steel Interconnect Applications

A study was conducted to explore the effects of Sr doping on the electrical properties of perovskite LaFeO3 thin-film protective conversion coatings grown onto a K41 ferritic stainless steel, a typical interconnect material for intermediate temperature solid oxide cell (SOC) applications. The Sr-doped coatings were prepared in La2O3- and SrO-containing molten carbonate baths with minor added amounts of nitrate salt for accelerated coating formation. For comparison purposes, undoped coatings were obtained using the same carbonate bath, with the only difference being that SrO was replaced by inert MgO. SEM/EDX and XRD analyses were used for coating characterization and confirmed the effective incorporation of Sr but not of Mg into the LaFeO3 layer. Although both the Sr-doped and undoped coatings consisted of a LaFeO3 layer grown above an inner Fe-Cr spinel, the coating thickness of the Sr-doped coating was distinctly higher, approximately 2 mu m, which is twice that of the undoped coating. Electrical measurements in terms of Area-Specific Resistance (ASR) were conducted at 700 degrees C in air and showed that Sr-doping significantly improved the electrical conductivity of the coated K41 steel. Due to the Sr-doping, the ASR values of the coated steel dropped from 60 to 37 m omega cm(2) after 300 h of exposure, in spite of the higher Sr-doped coating thickness. The study concludes that Sr-doped thin-film perovskite coatings appear to be a promising solution for improved SOCs steel interconnect stability at intermediate temperatures.