Atmospheric plasma spraying is a cost effective way to produce SOFC components. Doing so, sinter steps can be avoided, which is essential once a metallic support is used for the SOFC. Several properties are required regarding the micro structure of an optimized anode layer. Here gas permeability, electrochemistry, electronic conductivity, coefficient of thermal expansion as well as thermal shock resistance has to be considered. Different types of powder feedstock were investigated to develop an atmospheric plasma sprayed anode layer: (i) NiO or Ni together with YSZ as starting materials, (ii) agglomerates in which NiO and YSZ are already mixed on a sub-micrometer range, (iii) blended NiO/YSZ powder, (iv) separate injection of the individual NiO and YSZ powders, respectively into the plasma by two separate powder lines. The performance of APS anodes are measured in single fuel cell tests. Anode layers sprayed by a separate injection of the individual NiO and YSZ powders into the plasma show the best results.

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