h i g h l i g h t sMetal supported SOFC fabricated by plasma spraying with axial feedstock injection. Power density of 0.56 W cm À2 at 0.7 V was obtained at 750 C. Process parameter and feedstock property effects on anode composition investigated. Process parameter and feedstock property effects on anode microstructure investigated. a b s t r a c tComposite NieY 0.15 Zr 0.85 O 1.925 anodes were fabricated by axial-injection suspension plasma spraying in open atmosphere conditions. The composition of the anode is controllable by adjustment of the plasma gas composition, stand-off distance, and suspension feed rate. The total porosity is controllable through the addition of carbon black to the suspension as a sacrificial pore-forming material as well as by adjustment of the suspension feed rate. The size of the NiO particles in suspension affects both the composition and total porosity, with larger NiO particles leading to increased Ni content and porosity in the deposited coatings. The surface roughness increases with a decrease of the in-flight droplet momentum, which results from both smaller NiO particles in suspension and the addition of low density pore-forming materials. A solid oxide fuel cell was fabricated with both electrodes and electrolyte fabricated by axial-injection plasma spraying. Peak power densities of 0.718 W cm À2 and 1.13 W cm À2 at 750 C and 850 C, respectively, were achieved.

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Metal-supported SOFCs with power densities above 700 mW/cm2 at 750oC were fabricated by atmospheric plasma spraying, which can be readily automated and scaled for larger cell areas and production volumes, with no cell sintering requirement. Porous stainless steel substrates were dip-coated to protect against oxidation and chromium loss, followed by fabrication of the functional layers. Preliminary performance in hydrogen was found to be stable for 200 hours, with longer durability tests ongoing. Cells with modified anodes can achieve performances close to those of standard cells operating in hydrogen, with no evidence of coking in TGA methane experiments. Fabrication of anodes for hydrocarbon fuels and the results of scaling up from button cells to 5cm x 5cm cells are discussed.

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