本研究以新型的陶瓷成型技術─膠體鑄型技術來製作NiO-YSZ陽極管狀電極。雖然管狀電極具有易組裝性等優點，但對於管狀電極尺寸精度及成份均勻性等要求，難以傳統的乾壓成型技術來製作，因此以往的製程方式是利用注漿成型(slip casting)或射出成型(injection molding)等技術來製作，但以上兩種製程技術各有著燒結後尺寸不易控制或黏結劑含量較高在去黏結劑時間較久等缺點，因此製程參數難以控制。
藉由控制懸浮液的pH值及分散劑的添加量，來製備流動性質佳且穩定性高之膠體懸浮液，經除泡、注模、凝膠化、乾燥及去黏結劑後可成功製備管型。研究中顯示，在pH值為9~11且分散劑添加量為粉體重之0.2wt%時，具有最佳的流動性及穩定性，此一懸浮液的粘度適合用於灌鑄，並經由凝膠時間及溫度等變數控制，制定出合宜的聚合反應參數，隨後再經乾燥、去黏結劑及預燒等階段，運用電泳沉積技術成功在管狀電極上塗覆一層固態電解質(YSZ)薄膜。

A new ceramic forming technology, gelcasting , was used to fabricate tubular NiO-YSZ anode for solid oxide fuel cell applications in this study. Although the tubular design has more mechanical integrity , the conventional dry pressing did not suit for forming the tubular anode. It is due to the requirement of dimensional precision and homogenous constituents . In the past, the forming method for such a complex shape was only by slip casting or injection molding, but the problems including dimensional control and long de-binder procedure remain to be solved.

Before gelcasting, a highly fluidic and stable suspension was obtained by varying pH value and dispersant addition. When pH value was controlled at 9~11 and the dispersant addition was at 0.2wt%, the viscosity of this slurry lower than 0.7Pa was obtained. After casting into a mold, a 10cm long NiO/YSZ tube with 11mm diameter was successfully removed from the mold. Two different drying methods were used to remove moisture in the gelcasted tube. To avoid cracking due to inhomogeneous shrinkage during drying, the drying of gelcasted tube was first immersed in the ethanol solution with PEG2000 added and then followed by drying in the air. Although the dried tube was not deformed, the densification of gelcasted tube was also suppressed. On the other hand, when the drying of gelcasted tube was slowly conducted in the air by evaporation, the subsequent densification was significantly improved.

With proper control the polymerization rate of the slurry, a 10cm long NiO/YSZ tube was formed without noticeable defects. After de-molding, drying, and de-binder processes, a thin layer of YSZ electrolyte film was successfully deposited on the gelcasted NiO-YSZ anode tube by the electrophoretic deposition method.

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