Yttrium doped BaZrO3 (BZY) is a promising candidate as an electrolyte in anode-supported protonic ceramic fuel-cells for intermediate temperatures. Proton-conducting fuel-cells are typically fabricated in an anode-supported configuration where an electrolyte paste is deposited on the surface of calcined porous anode pellet and then sintered. The differences in sintering behaviour and thermal expansion coefficient can result in the development of elastic residual stresses that can affect the long-term stability of the cell under cyclic operation.
In this work, different sintering conditions, soaking time (5h and 10h) and sintering temperature (1200°C,1325°C and 1400°C), were used to fabricate half-cells of BZY20 (BaZr0.8Y0.2O(3-δ)) as the  electrolyte and BZY20/NiO as the anode using the solid-state reaction sintering method. The influence of the processing temperature and soaking time on the microstructure, surface finish and residual stress is proved and shown by detailed XRD and SEM characterization. Rietveld refinement of x-ray diffraction data was used to assess the presence of residual Y2O3 and BaY2NiO5 in the electrolyte layer as function of processing conditions, as well as to determine the amount of yttrium incorporated into the perovskite structure by means of an accurate determination of the lattice parameter. Residual stresses were measured using a specialized diffractometer with an Euler-type cradle and an area detector. Sintering experiments show that a temperature of 1400°C and shorter soaking times may be beneficial to a better formation of the BZY20 structure with larger grain sizes, better surface microstructure and presence of compressive residual stresses.