Numerical investigation of the influence of compositional volume ratios on interfacial thermal stresses in solid oxide fuel cells.

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Title: Numerical investigation of the influence of compositional volume ratios on interfacial thermal stresses in solid oxide fuel cells.
Authors: Zhang, Heng1 (AUTHOR) hzhang1027@163.com, Sarker, Mrittunjoy2 (AUTHOR), Li, Bing1 (AUTHOR), Yang, Haoyuan1 (AUTHOR), Kui, Dianlu1 (AUTHOR), Chang, Hong1 (AUTHOR), Ling, Yihan3 (AUTHOR)
Source: International Journal of Green Energy. Mar2026, Vol. 23 Issue 5, p979-994. 16p.
Subject Terms: *Solid oxide fuel cells, Thermal stresses, Taguchi methods, Material fatigue, Solid-solid interfaces
Abstract: Interfacial thermal stress is a primary driver of delamination and mechanical degradation in solid oxide fuel cells (SOFCs). A three-dimensional multiphysics model is developed to quantify interfacial thermal stress across four critical interfaces: the anode support layer (ASL)/anode functional layer (AFL), AFL/electrolyte layer (EL), EL/cathode functional layer (CFL), and CFL/cathode current collector layer (CCCL). An orthogonal design method is employed, comprising 36 configurations generated by four factors – solid-phase volume ratios (VRs) of Ni/yttria-stabilized zirconia (YSZ) in the ASL and AFL, and lanthanum strontium manganite (LSM)/YSZ in the CFL and CCCL – each varied at six levels. The results show that considerable thermal stress can arise even under seemingly balanced compositions, with maximum interfacial stress exceeding 60 MPa. Among the four factors, the CFL composition exerts the strongest influence, followed by the AFL composition, while the ASL and CCCL show minimal effects. Temperature variation remains minor, confirming that stress evolution is governed predominantly by elastic mismatch rather than thermal gradients. The optimal configuration – VRs of 0.2 (ASL), 1.5 (AFL), 0.5 (CFL), and 2.0 (CCCL) – minimizes stress across all interfaces by enhancing mechanical compliance and interlayer grading. Conversely, the most unfavorable case (2.0, 2.0, 3.0, 0.8) yields the highest stress. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Green Energy is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Numerical investigation of the influence of compositional volume ratios on interfacial thermal stresses in solid oxide fuel cells.
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  Label: Authors
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  Data: <searchLink fieldCode="AR" term="%22Zhang%2C+Heng%22">Zhang, Heng</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> hzhang1027@163.com</i><br /><searchLink fieldCode="AR" term="%22Sarker%2C+Mrittunjoy%22">Sarker, Mrittunjoy</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Li%2C+Bing%22">Li, Bing</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yang%2C+Haoyuan%22">Yang, Haoyuan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kui%2C+Dianlu%22">Kui, Dianlu</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chang%2C+Hong%22">Chang, Hong</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ling%2C+Yihan%22">Ling, Yihan</searchLink><relatesTo>3</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Green+Energy%22">International Journal of Green Energy</searchLink>. Mar2026, Vol. 23 Issue 5, p979-994. 16p.
– Name: Subject
  Label: Subject Terms
  Group: Su
  Data: *<searchLink fieldCode="DE" term="%22Solid+oxide+fuel+cells%22">Solid oxide fuel cells</searchLink><br /><searchLink fieldCode="DE" term="%22Thermal+stresses%22">Thermal stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Taguchi+methods%22">Taguchi methods</searchLink><br /><searchLink fieldCode="DE" term="%22Material+fatigue%22">Material fatigue</searchLink><br /><searchLink fieldCode="DE" term="%22Solid-solid+interfaces%22">Solid-solid interfaces</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Interfacial thermal stress is a primary driver of delamination and mechanical degradation in solid oxide fuel cells (SOFCs). A three-dimensional multiphysics model is developed to quantify interfacial thermal stress across four critical interfaces: the anode support layer (ASL)/anode functional layer (AFL), AFL/electrolyte layer (EL), EL/cathode functional layer (CFL), and CFL/cathode current collector layer (CCCL). An orthogonal design method is employed, comprising 36 configurations generated by four factors – solid-phase volume ratios (VRs) of Ni/yttria-stabilized zirconia (YSZ) in the ASL and AFL, and lanthanum strontium manganite (LSM)/YSZ in the CFL and CCCL – each varied at six levels. The results show that considerable thermal stress can arise even under seemingly balanced compositions, with maximum interfacial stress exceeding 60 MPa. Among the four factors, the CFL composition exerts the strongest influence, followed by the AFL composition, while the ASL and CCCL show minimal effects. Temperature variation remains minor, confirming that stress evolution is governed predominantly by elastic mismatch rather than thermal gradients. The optimal configuration – VRs of 0.2 (ASL), 1.5 (AFL), 0.5 (CFL), and 2.0 (CCCL) – minimizes stress across all interfaces by enhancing mechanical compliance and interlayer grading. Conversely, the most unfavorable case (2.0, 2.0, 3.0, 0.8) yields the highest stress. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Green Energy is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1080/15435075.2025.2587815
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 16
        StartPage: 979
    Subjects:
      – SubjectFull: Solid oxide fuel cells
        Type: general
      – SubjectFull: Thermal stresses
        Type: general
      – SubjectFull: Taguchi methods
        Type: general
      – SubjectFull: Material fatigue
        Type: general
      – SubjectFull: Solid-solid interfaces
        Type: general
    Titles:
      – TitleFull: Numerical investigation of the influence of compositional volume ratios on interfacial thermal stresses in solid oxide fuel cells.
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            NameFull: Zhang, Heng
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            NameFull: Sarker, Mrittunjoy
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            NameFull: Li, Bing
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            – D: 01
              M: 03
              Text: Mar2026
              Type: published
              Y: 2026
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