A composite ceramic separator of La(Ca)CrO
3/La(Sr)MnO
3 has been developed for a substrate-type, planar solid oxide fuel cell. La(Ca)CrO
3 was plasma-sprayed onto the porous thick La(Sr)MnO
3 substrate. As-sprayed films of calcium(II)-doped lanthanum chromate, La
0.7Ca
0.35Cr
0.95O
3 and La
0.8Ca
0.22Cr
0.98O
3 showed high gas permeability of 10
−7–10
−6 cm
4 g
−1 s
−1 and SEM observation showed surface cracks. After sintering the as-sprayed films at 1473 K for 2 h in air, the sintered films showed no surface cracks and showed improvement of gas permeability of less than 1 × 10
−8 cm
4 g
−1 s
−1. The peaks of CaCrO
4 and La
2CrO
6 were observed in the XRD spectra of the powders and as-sprayed films for both components of La(Ca)CrO
3. However, those peaks disappeared and the peaks of La
2O
3 and CaO were observed in the sintered films. The lattice parameters of the sintered films of La
0.7Ca
0.35Cr
0.95O
3 were larger than those of the as-sprayed films, whereas those of La
0.8Ca
0.22Cr
0.98O
3 were almost same before and after the sintering. WDX-SEM analysis of the sintered films of La
0.7Ca
0.35Cr
0.95O
3 showed that CaO precipitated like an island on the surface of the sintered films. During the sintering process, dissolution of CaCrO
4 and La
2CrO
6 seems likely to promote sintering of La(Ca)CrO
3. However, La
2O
3 and CaO precipitated from the melted CaCrO
4 and La
2CrO
6 accompanied with the sintering process of La(Ca)CrO
3. Because of the low CaO precipitation in the sintered films, La
0.8Ca
0.22Cr
0.98O
3 is considered to be preferable materials for solid oxide fuel cell composite ceramic separators.
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