A numerical model was developed to evaluate the performance of detailed solid oxide fuel cell (SOFC) anode microstructures obtained from experimental reconstruction techniques or generated from synthetic computational techniques. The model is also capable of identifying the linear triple phase boundary (TPB) reaction sites and evaluating the effective transport within the detailed structures, allowing a comparison between the structural properties and performance to be conducted. To simulate the cell performance, a novel numerical coupling technique was developed in OpenFOAM and validated. The computational grid type and mesh properties were also evaluated to establish appropriate mesh resolutions to employ when studying the performance. The performance of a baseline synthetic electrode structure was evaluated using the model and under the applied conditions it was observed that the ionic potential had the largest influence over the performance.

The model was used in conjunction with a computational synthetic electrode manufacturing algorithm to conduct a numerical powder to power parametric study investigating the effects of the manufacturing properties on the performance. An improvement in the overall performance was observed in structures which maximized the number of reaction sites and had well established transport networks in the ion phase. From the manufacturing parameters studied a performance increase was observed in structures with low porosity and ionic solid volume fractions near the percolation threshold, and when the anodes were manufactured from small monosized particles or binary mixtures comprising of smaller oxygen ion conductive particles. Insight into the anode thickness was also provided and it was observed that the current distribution within the anode was a function of the applied overpotential and an increase in the overpotential resulted in the majority of the current production to increase and shift closer to the electrode-electrolyte interface.