Abstract: A method for treating a porous item constructed of metal powder, such as a powder made of Series 400 stainless steel, involves a step of preheating the porous item to a temperature of between about 700 and 900° C. degrees in an oxidizing atmosphere and then sintering the body in an inert or reducing atmosphere at a temperature which is slightly below the melting temperature of the metal which comprises the porous item. The thermal stability of the resulting item is enhanced by this method so that the item retains its porosity and metallic characteristics, such as ductility, at higher (e.g. near-melting) temperatures.

Abstract: A fuel cell unit includes an array of solid oxide fuel cell tubes having porous metallic exterior surfaces, interior fuel cell layers, and interior surfaces, each of the tubes having at least one open end; and, at least one header in operable communication with the array of solid oxide fuel cell tubes for directing a first reactive gas into contact with the porous metallic exterior surfaces and for directing a second reactive gas into contact with the interior surfaces, the header further including at least one busbar disposed in electrical contact with at least one surface selected from the group consisting of the porous metallic exterior surfaces and the interior surfaces.

Abstract: An internal current collector for use inside a tubular solid oxide fuel cell (TSOFC) electrode comprises a tubular coil spring disposed concentrically within a TSOFC electrode and in firm uniform tangential electrical contact with the electrode inner surface. The current collector maximizes the contact area between the current collector and the electrode. The current collector is made of a metal that is electrically conductive and able to survive under the operational conditions of the fuel cell, i.e., the cathode in air, and the anode in fuel such as hydrogen, CO, CO2, H2O or H2S.