The use of ceramic materials in the production of solid oxide fuel cells (SOFCs) is one of the most innovative applications of these materials in recent years. The aim of this work is to assess how to obtain a complete, self-assembled SOFC (supported by electrolyte) using atmospheric plasma spray (APS) to spray the three different ceramic layers of the assembly. One of the main problems of SOFC production is the high cost of the process; the hypothesis is that these costs can be reduced by forming the three ceramic layers of the SOFC by APS technology. The anode (YSZ-NiO), cathode (LSM), and electrolyte (YSZ) layers can be produced by APS with reasonable efficiency. Another problem with SOFC manufacture is assembly and adhesion of the three layers; the creation of gradual transition layers by APS improves these aspects of the production process. Chemical and structural characterization of the feedstock powders and resultant ceramic layers was performed by laser scattering, XRD, SEM, and confocal microscopy, and the results confirmed the efficiency of the attained APS-SOFC components.

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