Reformate Fueled SOFC
In addition to FFC’s line of unique DOSOFC materials, we have developed and made available for purchase full cells and half cells (in planar and tubular forms) based on the more conventional multi-layer Nickel cermet anode, 8 mole % YSZ or 6-to-10 mole % ScSZ electrolyte, and either LSM or LSCF multi-layer cathode. Please feel free to discuss your specific application with one of our development engineers for assistance determining the optimal cell configuration.

Anode, Electrolyte and Cathode Materials
The same materials that we use to produce all of our mechanically-robust and high-performance fuel cells are available for purchase separately. Green (un-fired) anode and electrolyte tapes in a range of chemistries, formulations and thicknesses can be produced to your specifications or may be available “off the shelf” in combinations that are known to work and have been fully characterized in our laboratory. We also provide cathode paste – by the gram, kilogram or ton – for LSM and LSCF in chemistries appropriate for functional, as well as current collection, layers. A full range of contact pastes (NiO, Ag, Ag-Pd, Au, Pt and LSM) are also available.

Ceramic Tapes (Tape Casting or Slip Casting)
Tape casting is the process by which a precisely-combined and expertly-dispersed mixture of inorganic materials (most commonly: ceramic powders and organic materials that may include binders, plasticizers, dispersants and other rheological modifiers) are deposited onto a carrier tape – most commonly a coated polyester – to an even thickness controlled by means of a “doctor blade”. After drying, this relatively thin (thicknesses between 2-5 µm and 1 mm are common), flexible “tape” is removed, cut to a desired shape and fired. Alternatively, this unfired, or “green”, tape can be processed again to deposit another layer on its surface, or laminated using a process like hot isostatic pressing (HIP) to produce a multi-layer structure that, when appropriately formulated, laminated and fired, will produce a flat, strong, intimately-connected, engineered material with a desired set of properties.

Franklin AM – via FFC – has more than seven years of experience designing some of the most complex tape systems ever produced. We routinely cast, laminate and fire combinations of both dense and porous tapes. These tapes ultimately produce structures that combine highly-porous layers (50 to 70% porosity) adjacent to functionally-dense ones, combining them into a single part that fires flat – flat enough to screen print without fear of cracking.

This ability to design slurry, tape casting, lamination and firing processes in a way that compensates for inherent incompatibilities between the properties of dense and porous ceramic materials and dissimilar ceramic materials is one of our company’s core competencies and a unique technical capability that we offer to our customers.

You will find in our store tape systems for SOFC applications that include a multi-layer NiO/6ScSZ anode and a 6ScSZ or 10ScSZ electrolyte in thicknesses of 5 to 20 µm. These systems fire flat when processed according to our recommendations. You will also find many other material formulations and compositions. Please let us know what your fuel cell, sensor, LTCC, HTCC or LED application requires and let us design a tape system that meets your specifications at the lowest possible manufacturing cost.

Thick Film Paste Processing
Screen printable pastes, also known as inks, are produced by precisely mixing metal and / or ceramic powders (optionally, glass powders and inorganic oxides), along with organic materials, and thoroughly combining these by a mixing process commonly known as three-roll milling (3RM).
Franklin AM brings together state-of-the-art, hydraulically-controlled three-roll mill equipment, experienced manufacturing and product engineers and technicians, along with designs for six sigma (DFSS) and ISO 9001 quality procedures, to the art of producing thick-film paste products that are second to none in performance and quality. Our paste products include SOFC cathodes, anodes, and electrolytes, and metallization products for LTCC, HTCC, and solar cell applications.

Manufacturing Materials
Here, you can also find materials for use in your own tape casting, paste manufacturing or firing processes. These include a line of proprietary Terpineol- and Texanol-based vehicles and thinners. We can also provide porous and dense setter / cover plate materials in alumina and zirconia compositions that are custom made to your specific dimensional requirements.