Advanced R&D under numerous DOE Contracts paving the way for commercialization of SOFC Systems• Processing-Microstructure-Property relationships with significant performance and lifetime gains• Scale-up of Ceramic Proton conducting fuel cell and electrolyzer cells• Developed Multilayer-Cocasting method for Roll-2-Roll processing• Cell QC documentation and Gage R&R Efforts• Performance and reliability evaluation

Material ResearchDeveloped Laboratory to make SOFC cells on a small scale where techniques can be improved and validated. Providing a few cells for FCE system design validation projects and other research efforts.

Provide specialized expertise to further fuel cell research efforts; consulting on: 1) Slip formulations for tape casting of anode substrate and electrolyte materials; 2) Cell and stack design to optimize performance; 3) Screen printing inks of cathode materials; and 4) Optimum processing conditions.

• Managed laboratory dedicated to materials development for MSRI’s contract under DOE’s SECA project (at University). Over 30 tape variations made and tested for fuel cell performance and flexural strength before and after reduction.• Developed slip formulations for tape casting of both anode substrate materials along with very thin layers (5-10 micron after sintering) cast and laminated onto anode substrate tape which were then co-sintered. Method led to increased efficiency, performance, and reliability.• Developed screen printing inks of cathode materials and optimized the processing conditions to get the best performance. Button cell performance was increased from 0.8 W/cm2 to 2.1 W/cm2 and in stack performance improved around 30%• Experimented with catalyst infiltration of the cathode which yielded sharp increases in performance. Method is easily scalable and allowed us to research different materials quickly and efficiently.• Supervised processing efforts and developed QC methods and reporting routines. Developed database of cell measurements and tracking efforts while led to an increase in manufacturing yields and reliability in cell production. Using these methods we were able to increase production by 70%.• Successfully coated interconnects with protective coatings and improved thermal expansion coefficient mismatch of these coatings.• Developed ‘Spray Paint’ formulation for applying ceramic materials as a thin and/or thick coat to uneven surfaces with great interfacial bonding.• Developed unique method of applying BACS glass tape to Mica paper. Greatly simplified stacking process and performed very well in stack operation and thermo-cycling performance.

Worked under my graduate advisor: Dr. Anil Virkar

• In a project dedicated to finding/developing interconnect materials for high temperature operation: Measured conductivity of oxide scale that formed at high temperature in both oxidizing and reducing environments of different alloy compositions as well as measuring the growth kinetics of the scale.• Successful in finding Haynes 230 Ni alloy material and demonstrating its superior properties. Explored other alloys with powder metallurgy and the results were published by Diane England.• Developed procedures for laminating anode support tape for making fuel cell parts in a die in order to put the flow channels directly into the finished part.

Supervised QC efforts and audited reports from 8 field inspectors in regards to soil compaction testing and concrete strength assurance in compliance with the contract SOP.Answered audits by UDOT.Managed Certification records for bridges and other structures along the I-15 reconstruction corridor.