Hybrid deposition of thin film solid oxide fuel cells and electrolyzers

A method for producing solid oxide fuel cells using continuous deposition, comprising:

• forming an electrode having about 55%-25% porosity and a metal content of less than 15% by volume using a planar magnetron from a material selected from the group consisting of yttria stabilized zirconia and other material that matches the coefficient of thermal expansion of an associated electrolyte, coated with a material selected from the group consisting of silver, platinum, and palladium;
• forming an electrode-electrolyte interface composed of material selected from the group consisting of yttria stabilized zircornia, and CeO.sub.2 on at least one surface of the porous electrode;
• forming an electrolyte composed of an ion conducting oxide on the interface;
• forming an interface on the electrolyte composed of material selected from the group consisting of yttria stabilized zirconia, and CeO.sub.2 ;
• and
• forming a porous electrode having a metal content of less than 15% by volume using a planar magnetron from a material selected from the group consisting of yttria stabilized zirconia and other material that matches the coefficient of thermal expansion of the electrolyte, coated with a material selected from the group consisting of nickel, iron, cobalt, and Co--Fe alloys.

A continuous deposition process for producing a solid oxide fuel cell, comprising:

• forming a first porous electrode having a porosity of 25%-55% and a metal content of less than 15% by volume;
• forming a first electrode-electrolyte interface composed of material selected from the group consisting of yttria stabilized zirconia, and CeO.sub.2 on a surface of the porous electrode;
• forming an electrolyte composed of an ion conducting oxide on the first interface;
• forming a second electrode-electrolyte interface on the electrolyte composed of material selected from the group consisting of yttria stabilized zirconia and CeO.sub.2 ;
• forming a second porous electrode having a metal content of less than 15% by volume on the second interface;
• forming another electrode-electrolyte interface on one or both of said porous electrodes;
• forming an eletrolyte layer on one or both of the thus formed another interface;
• and
• forming an electrode-electrolyte interface on one or both electrolyte layers;
• and
• forming a porous electrode on one or both of the thus formed electrode-electrolyte interfaces.