Atmospheric plasma spraying is attractive for manufacturing solid oxide fuel cells (SOFCs) because it allows functional layers to be built rapidly with controlled microstructures. The technique allows SOFCs that operate at low temperatures (500 to 700 °C) to be fabricated by spraying directly onto metallic supports. However, standard cathode materials used in SOFCs have high polarization resistance at low temperatures, necessitating alternative materials. In this study, coatings of lanthanum strontium cobalt ferrite (LSCF) were fabricated on steel substrates using axial-injection atmospheric plasma spraying. Coating thickness and microstructure were evaluated and X-ray diffraction (XRD) analysis was performed to detect material decomposition and the formation of undesired phases in the plasma. The results define the envelope of plasma spray parameters for depositing LSCF coatings and the conditions in which composite cathode coatings can be produced.

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