TWO-LAYER COATINGS ON METAL SUBSTRATES AND DENSE ELECTROLYTE FOR HIGH SPECIFIC POWER METAL-SUPPORTED SOFC

1 . A method comprising:

forming an electroconductive ceramic layer on a porous metal support;

forming a ceramic anode layer on the electroconductive ceramic layer;

forming a ceramic electrolyte layer on the ceramic anode layer; and

forming a ceramic cathode layer on the ceramic electrolyte layer.

2 . The method as recited in claim 1 , wherein:

forming the electroconductive ceramic layer comprises sintering the electroconductive ceramic layer;

forming the ceramic anode layer comprises sintering the ceramic anode layer; and

forming the ceramic electrolyte layer comprises using ion-assisted electron beam physical vapor deposition to deposit the ceramic electrolyte layer on the ceramic anode layer.

3 . A method of limiting oxidation of a chromium-containing metal support in a fuel cell, the method comprising:

using an electroconductive ceramic barrier layer between a chromium-containing metal support and a ceramic electrode layer disposed on the chromium-containing metal support, the electroconductive ceramic barrier layer including a ceramic material selected from a group consisting of lanthanum-doped strontium titanate and perovskite oxides.

4 . A method of processing a fuel cell, the method comprising:

providing a substrate that includes:

a chromium-containing metal support;

a ceramic electrode layer on the metal support; and

an electroconductive ceramic layer between the chromium-containing metal support and the ceramic electrode layer, the electroconductive ceramic layer includes a ceramic material selected from a group consisting of lanthanum-doped strontium titanate and perovskite oxides; and

depositing a dense ceramic electrolyte layer on the ceramic electrode layer.