Review
Cutting-edge fabrication strategies and low-temperature sintering approaches for manufacturing solid oxide electrolysis cells
Chain | Vol., Issue 2, 2026 |
pp. 152-186
Steam electrolysers are a key technology for high-efficiency hydrogen production,
offering superior thermodynamic performance compared with liquid-water electrolysis
when operated at elevated temperatures. Despite these advantages, their wider deployment
remains constrained by manufacturing complexity, component cost, and stringent processing
requirements for ceramic membranes, electrodes, and interconnect-related components.
This mini-review provides a comprehensive assessment of fabrication strategies relevant
to steam-electrolyser manufacturing, encompassing compression-based forming, colloidal
processing, fibre- and ink-based deposition techniques, as well as physical vapour
deposition. Particular attention is given to how electrode architecture, cell geometry,
and interfacial compatibility influence viable processing routes and manufacturability,
rather than device operation at the single-cell level. Emphasis is placed on solid-state
ceramic membranes and electrodes based on gadolinium-doped ceria (GDC) and yttria-stabilised
zirconia (YSZ), which remain central to current and emerging steam-electrolyser technologies.
Because most scalable fabrication routes ultimately depend on controlled densification
and microstructural optimisation of polycrystalline ceramics, the review critically
examines low-temperature sintering mechanisms, including grain-boundary-activated
densification, transient liquid-phase formation, and nano-powder engineering. Recent
advances in single- and multi-element sintering aids are discussed, with co-doping
strategies shown to reduce densification temperatures by several hundred degrees while
preserving ionic conductivity and long-term stability. A quantitative techno-environmental
analysis further demonstrates that reducing electrolyte sintering temperatures from
1,400℃ to 650℃–950℃ can lower energy consumption by 30%–55%, reduce fabrication costs,
and significantly decrease CO2 emissions associated with manufacturing. By integrating fabrication methodologies
with low-temperature processing chemistry in a steam-electrolysis–relevant context,
this review highlights the key materials–process interactions governing manufacturability
and identifies future research directions for scalable, durable, and economically
competitive steam-electrolyser technologies.
DOI: 10.23919/CHAIN.2026.000009 Cited: 0 Download: 0
