Model-Guided Interconnect Topology Engineering Boosts SOEC Electrode Performance Realization

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This study develops a high-accuracy multiphysics model for solid oxide electrolysis cell (SOEC) stacks, experimentally validated over a broad steam mole fraction range (0.3–0.9) with >96% prediction accuracy. Industrial-scale stacks often fail to achieve the ideal performance of electrode materials observed in small-area laboratory tests. For cost-effective SOEC industrialization, and inspired by the design philosophy of structural topology optimization, three innovative interconnect designs - fine-channel, cathode-widened, and trapezoidal - are engineered based on a conventional straight-channel design at identical fabrication costs ($0.12 cm −2 ). These structures enhance i-V characteristics, energy consumption efficiency, and hydrogen production: specifically, the fine-channel design reduces energy consumption by 8% vs conventional structure at 8,600 A m −2 ; cathode-widening lowers electrolysis voltage by 10.7%, enabling stable 10,000 A m −2 operation; and the trapezoidal structure further enhances performance (11.2%; 10,200 A m −2 ) while increasing hydrogen output by 18% at 1.35 V. Mechanistic analysis identifies reactant concentration, steam pressure, vertical gas flux, current density distribution, and flow velocity as governing factors, with steam supply and transport stability being critical. The proposed design principles are reference-geometry-independent for facilitating full exploitation of SOEC electrode material performance, demonstrating broad applicability for SOEC optimization and green hydrogen advancement.

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