Fracture and Delamination Prediction in Solid Oxide Electrolysis Cells via Multiphysics Finite Element Simulation in ANSYS
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Reliable high-temperature hydrogen production depends on solid oxide electrolysis cells (SOECs) with long operational lifetimes. However, SOECs undergo electrochemical heat generation, oxygen partial-pressure loading, and thermal-expansion mismatch between multilayer components. These coupled effects induce bulk cracking, interfacial debonding, and sealant degradation, ultimately compromising structural integrity. Accurate multiphysics modeling of these interacting fields is therefore essential to predict failure initiation and guide the design of more durable SOEC systems. This work develops a coupled thermo–electro–mechanical finite element framework in ANSYS for analyzing both bulk fracture and interfacial damage in planar SOEC architectures. Material definitions incorporate temperature-dependent properties, creep behavior, and microstructural changes reported in long-term operational studies [1–2]. For bulk ceramic layers, a Continuum Damage Mechanics (CDM) formulation inspired by mechanistic SOFC/SOEC damage models is employed, in which microcracking and porosity-driven stiffness degradation are represented through evolving internal damage variables. Interfacial delamination is modeled using cohesive-zone formulations following recent SOEC debonding simulations and validated cohesive element strategies [3], enabling representation of mixed-mode separation and progressive traction degradation. Preliminary simulations identify stress concentrations, critical deformation, and high-risk interfaces consistent with experimentally observed failure mechanisms. Ongoing work focuses on evaluating energy-release rates and damage evolution along electrode–electrolyte and sealant–metal interfaces under varying temperature, operating voltage, and geometric parameters. The resulting framework integrates multiphysics loading, CDM-based bulk damage, and cohesive interfacial failure into a predictive tool for assessing SOEC structural integrity and supporting the development of more reliable high-temperature electrolysis systems.
