Freeze tape casting was used to fabricate a porous metal support for the solid oxide fuel cell (SOFC). The parameters that affect tape quality, such as casting temperature, solids loading, amount of additives and particle size of steel powders, have been investigated. It was found that casting temperatures between -40°C and -80°C did not affect pore size and structure of the metallic tapes. The porosity and shrinkage rate of the metallic tapes is highly influenced by the solids loading, but not by the particle size of the steel powders. Multiple layers of the single cell structure were deposited on the freeze cast green tape by screen printing. A composite cathode of nano-size lanthanum strontium manganite (LSM) plus YSZ was obtained by infiltration.

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