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A Sungkyunkwan University (SKKU) team has addressed one of the most stubborn weak points in protonic ceramic electrochemical cells (PCECs): the microscopic interface where a dense electrolyte meets a porous electrode. Using a thin interlayer deposited by precursor-based electrostatic spray deposition, the researchers increased physical contact, reduced interfacial resistance and improved both power output and operating durability.
The result is a reversible cell that can generate electricity from hydrogen in fuel-cell mode or produce hydrogen in electrolysis mode. The reported process also worked with ammonia and methane and was demonstrated on large-area substrates, although the technology remains at the research stage rather than being a commercial product.
What the SKKU coating changes
In a PCEC, the electrolyte and electrode must meet across a large area so ions, electrons and electrochemical reactions can move efficiently between them. The electrolyte is dense, while the electrode is porous. Even when the two layers appear joined, microscopic gaps can leave much of the nominal interface inactive. Those gaps create interfacial contact resistance, wasting energy as heat and restricting the reaction area.
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Outbyte PC Repair FREEClear out junk files and repair common Windows errorsFree Scan →Outbyte Driver Updater FREEScan for outdated or missing drivers - takes under a minuteDriver Scan →SKKU’s method places a thin, dense nanointerlayer over the electrolyte using precursor-based electrostatic spray deposition. The coating fills and smooths the microscopic interface, increasing the proportion of the surfaces that are physically touching. The team calls this proportion contact coverage. In the Nature Communications study, measured coverage reached 92.6 ± 0.6%.
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Equivalent-circuit impedance modeling showed that the improved interface lowered both ohmic resistance and polarization resistance. In practical terms, less of the applied voltage is consumed overcoming the interface, leaving more of the cell’s electrical or chemical driving force available for the intended reaction.
What a protonic ceramic electrochemical cell is
A protonic ceramic electrochemical cell is a high-temperature ceramic device whose electrolyte conducts protons. It can be operated in two directions:
- Fuel-cell mode: hydrogen is supplied as fuel and the cell converts its chemical energy into electricity.
- Electrolysis mode: electricity is supplied to drive the reverse reaction and produce hydrogen.
The reversible design matters because one platform can support power generation and hydrogen production, depending on the operating conditions and the surrounding energy system. The SKKU work focuses on making the shared electrolyte-electrode interface efficient enough to support both modes.
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Measured performance in the 2026 Nature Communications study
The main experiment reported the following results at 500 °C:
| Operating mode | Condition | Reported result | What it measures |
|---|---|---|---|
| Fuel cell | 500 °C | 1.01 W/cm² peak power density | Electrical power produced per active cell area |
| Electrolysis | 500 °C, 1.3 V | 1.15 A/cm² current density | Hydrogen-producing electrolysis rate per active cell area |
| Interface | Measured contact area | 92.6 ± 0.6% coverage | Share of electrode-electrolyte surfaces in physical contact |
These are laboratory performance figures from the Nature Communications research team in 2026. Peak power density is not the same as average output over a complete system, and current density at a specified voltage does not by itself establish total hydrogen production without the cell’s active area and operating time.
Why the interface also improves durability
A ceramic cell repeatedly expands and contracts as it heats, cools and changes operating mode. Poorly connected layers can concentrate stress at microscopic gaps, eventually causing delamination. The SKKU team reports that the improved interface increased mechanical integrity, resisted delamination during harsh thermal cycling and supported long-term operational stability.
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The coating therefore addresses two linked problems: electrical losses caused by incomplete contact and mechanical failure caused by a weak bond. Better contact is useful only if it survives cycling; the reported results indicate that the interlayer was designed to provide both functions rather than maximizing initial output at the expense of lifetime.
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Fuel flexibility: hydrogen, ammonia and methane
The sources report stable operation with direct fueling using hydrogen, ammonia and methane. That broadens the potential operating envelope beyond a cell supplied only with purified hydrogen. It also makes the interface relevant to systems that may have to switch among available fuels.
Fuel compatibility in these experiments should not be read as proof that every balance-of-plant requirement has been solved. Fuel processing, gas cleanup, thermal management and emissions control remain system-level engineering issues. The demonstrated point is narrower and important: the coated PCEC maintained stable cell performance when those fuels were used.
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How this result compares with a related SKKU-linked study
A separate ACS Nano study linked to SKKU reported a related solid-oxide electrochemical-cell result. It should not be treated as the same experiment or as an additional measurement of the 500 °C PCEC device.
| Study | Coating and temperature | Fuel-cell result | Electrolysis result | Durability evidence |
|---|---|---|---|---|
| Nature Communications, 2026 | Interface nanointerlayer; 500 °C | 1.01 W/cm² peak power density | 1.15 A/cm² at 1.3 V | Improved thermal-cycling integrity, delamination resistance and long-term stability |
| Related ACS Nano study | Approximately 50 nm La0.6Sr0.4CoO3 nanocoating; 700 °C | 1.46 W/cm² peak power density | 1.78 A/cm² at 1.3 V | Sequential 100-hour operation at 1.0, 1.5 and 2.0 A/cm² |
The higher figures in the ACS Nano study were obtained at 700 °C under a different cell configuration. Comparing the numbers without accounting for temperature, materials and test protocol would be misleading.
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Electrostatic spray deposition uses an electrically charged precursor spray to place the interlayer with controlled coverage. SKKU describes the process as low-cost, scalable and suitable for large-area substrates. The university announcement also reports uniform fabrication on larger substrates, an important step beyond producing a coating only on small laboratory coupons.
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Manufacturing scale is a separate challenge from cell performance. A process must maintain thickness, composition and contact uniformity across a larger area while remaining compatible with stack assembly and thermal processing. The reported large-area demonstration suggests the deposition method has been considered with that constraint in mind, but it is not evidence of mass production.
What has—and has not—been commercialized
SKKU presents the interface process as potentially relevant to large-scale clean-energy plants, hydrogen-powered vehicles and energy-storage systems. Those are prospective applications. The available reports do not document a commercial product, deployed plant, licensing agreement, retail component or verified commercial partner.
For now, the most accurate description is a research-stage interface-engineering technology. Its significance is that a measurable microscopic variable—contact coverage—was connected to lower interfacial resistance, higher reversible-cell performance and better mechanical durability using a deposition process intended to scale.
What to watch in future validation
- Whether the 92.6% contact coverage can be reproduced across full-size cells and multi-cell stacks.
- How power and hydrogen-production rates change after extended thermal cycling beyond the reported tests.
- Whether ammonia and methane operation remains stable under practical fuel impurities and load changes.
- How deposition speed, precursor use and thermal processing affect manufacturing cost.
- Whether stack-level efficiency and lifetime retain the advantages measured on individual cells.
Professor Wonyoung Lee summarized the engineering principle behind the work: “No matter how advanced a new material may be, it cannot deliver its full performance if the interfaces between components are not properly connected.” The SKKU results put numbers on that principle and show why interface design can be as consequential as the bulk materials in a hydrogen-conversion device.
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