Production and Reliability Oriented SOFC Cell and Stack Design M. Hauth a , V. Lawlor a , P. Cartellieri a , C. Zechmeister b , S. Wolff b , C. Bucher b J. Malzbender c , J. Wei c , A. Weber d , G. Tsotridis e , H. L. Frandsen f , K. Kwok f T. T. Molla f , Z. Wuillemin g , J. Van herle h , F. Greco h , T. Cornu h , A. Nakajo h , A. Atkinson i L. Vandeperre i , X. Wang i a AVL List GmbH, Hans-List-Platz 1, 8020 Graz, Austria b Dynardo Austria GmbH, Wagenseilgasse 14, 1120 Wien, Austria c Forschungszentrum Jülich GmbH, Institute for Energy and Climate Research, IEK-2 52425 Jülich, Germany d Institute for Applied Materials (IAM-WET), Karlsruher Institut für Technologie (KIT) Adenauerring 20b, 76131 Karlsruhe, Germany e European Commission, Joint Research Centre, Directorate C: Energy, Transport and Climate, Petten, The Netherlands f DTU, Frederiksborgvej 399, 4000 Roskilde, Denmark g SOLIDpower-HTceramix, 26 av. des Sports, 1400 Yverdon-les-Bains, Switzerland h EPFL Valais, rue de l’Industrie 17, 1951 Sion, Switzerland i Imperial College, London, SW7 2AZ, UK This paper presents an innovative development methodology for a production and reliability oriented SOFC cell and stack design aiming at improving the stacks robustness, manufacturability, efficiency and cost. Multi-physics models allowed a probabilistic approach to consider statistical variations in production, material and operating parameters for the optimization phase. A methodology for 3D description of spatial distribution of material properties based on a random field models was developed and validated by experiments. Homogenized material models on multiple levels of the SOFC stack were established. The probabilistic models were related to the experimentally obtained properties of base materials to establish a statistical relationship between the material properties and the most relevant load effects. Software algorithms for meta models that allow the detection of relationships between input and output parameters and to perform a sensitivity analysis were developed and implemented. The capabilities of the methodology are illustrated on two practical cases. Introduction This paper reports the results from the European project PROSOFC. Within the project an innovative methodology for a production and reliability oriented SOFC cell and stack design is developed. In particular the PROSOFC project aims at improving the robustness, manufacturability, efficiency and cost of SOLIDpower state-of-the-art SOFC stacks so as to reach market entry requirements. The key issues are the mechanical robustness of SOFCs, and the delicate interplay between cell properties, stack design, and operating conditions of the SOFC stack.