Metal-supported solid oxide fuel cells (MS-SOFCs) represent a promising advancement for intermediate-temperature energy conversion applications due to their enhanced mechanical robustness and rapid startup capabilities. This investigation systematically evaluates the correlation between yttria-stabilized zirconia (8YSZ) electrolyte thickness and electrochemical performance in NiFe-supported architectures. Three distinct cells featuring YSZ electrolyte thicknesses of 7.05, 14.2, and 21.2 μm were fabricated via tape casting and co-sintering at 1,350 °C, while maintaining identical NiFe support (280 μm) and Ni-YSZ anode (22 μm) thicknesses. Electrochemical characterizations revealed a clear inverse relationship between electrolyte thickness and cell performance. The cell with the thinnest electrolyte (7.05 μm) achieved the highest power density of 0.32 W/cm2 at 800 °C, representing a 4.6-fold improvement compared to the thickest variant (21.2 μm). Electrochemical impedance spectroscopy and distribution of relaxation times analysis confirmed that ohmic resistance dominated the total cell impedance, and scaled linearly with electrolyte thickness, while electrode kinetics remained consistent. This study establishes that thin YSZ electrolytes (≤ 8 μm) prepared via co-sintering fabrication maximize MS-SOFC performance while maintaining structural integrity, providing an essential design for high-performance metal-supported fuel cell development.

Abstract
1. Introduction
2. Experimental Procedure
3. Results and Discussion
Acknowledgement
References
Author Information

• Zheng Dao Jin(Department of Materials Science and Engineering, Dankook University, Cheonan 31116, Republic of Korea)
• Sang Eun Lee(Department of Materials Science and Engineering, Dankook University, Cheonan 31116, Republic of Korea)
• Mohammed Kamal Warshi(Hydrogen Research Center, Dankook University, Cheonan 31116, Republic of Korea, Department of Materials Science and Engineering, Dankook University, Cheonan 31116, Republic of Korea)
• Hee Jung Park(Hydrogen Research Center, Dankook University, Cheonan 31116, Republic of Korea, Department of Materials Science and Engineering, Dankook University, Cheonan 31116, Republic of Korea) Corresponding author
• Kyoung-jin Lee(Wonik Materials, Chungju 28219, Republic of Korea)