Nanocrystalline, single phase, and highly homogeneous La0.84Sr0.16MnO3 (LSM) powder was prepared by a unique spray‐pyrolysis process for solid oxide fuel cell applications. Atomization of a citrate–nitrate precursor solution consisting of La3+, Sr2+, and Mn2+ ions in the molar ratio 0.84:0.16:1.0, which can initiate a controlled exothermic anionic oxidation‐reduction reaction leading to a self‐propagating auto‐ignition (self‐ignition) reaction within individual droplets led to the conversion of the precursor to their corresponding single‐phase LSM powder. Characterization of the as‐sprayed and calcined products by X‐ray powder diffraction, thermal analysis, and microstructural analysis confirmed the formation of nanocrystalline single‐phase LSM powder by this process.

Fused silica ceramics was prepared by using conventional organic binder, mathacrylamide‐N,N′‐methylenebisacrylamide (MAM‐MBAM) system by gelcasting process. Mechanical properties of green bodies were studied as a function of solid loading varying from 60 to 72 vol%. After evaluating the green body mechanical properties, the samples were densified at different sintering temperature from 1200 to 1450°C with definite intervals of 50°C and subjected to flexural strength analysis. Variation in flexural strength with sintering temperature was observed and correlated with the quantity of devitrification of fused silica during sintering. Quantification of devitrified cristobalite was carried out by using 20 wt% rutile (TiO2) as an internal standard by X‐ray diffraction. It was found that, as the cristobalite content increased, flexural strength decreased. Reliability studies were carried out for the samples having maximum flexural strength with and without crystalline content. Reliability studies have shown that for this organic binder system the sample sintered at 1300°C is crystalline free and most reliable product. The mechanical properties and reliability of this product processed with organic binder are compared with inorganic binder system. Results indicate that the sample fabricated using inorganic binder system is exhibiting high Weibull modulus and thus better reliability.