Abstract: A ceramic precursor mixtures for extrusion and firing into porous ceramics. The ceramic precursor mixtures include ceramic beads and green inorganic shear binder agglomerates. The green inorganic shear binder agglomerates can include inorganic filler particles and a polymeric binder. The green inorganic shear binder agglomerates can deform under an applied shear stress during mixing and/or extrusion such that they are smeared into a plurality of interbead gaps between adjacent ceramic beads or pore former particles. During firing, the smeared green inorganic shear binder agglomerates can sinter and react to form ribbons extending between, and interconnecting adjacent ceramic beads.

Abstract: A ceramic article and method of manufacturing. The ceramic article comprises a porous ceramic material having a microstructure comprising an interconnected network of porous spheroidal ceramic beads. The microstructure has a total open porosity defined as the sum of an open intrabead porosity of the beads and an interbead porosity defined by interstices between the beads in the interconnected network. The microstructure has a bimodal pore size distribution having an intrabead peak corresponding to the open intrabead porosity and an interbead peak corresponding to the interbead porosity. An intrabead median pore size of the intrabead porosity is less than an interbead median pore size of the interbead porosity.

Abstract: A particulate filter and method of manufacture. The particulate filter comprises a ceramic honeycomb body comprising a plurality of intersecting walls that define a plurality of channels extending longitudinally though the ceramic honeycomb body. The intersecting walls comprise a porous ceramic material having a microstructure that comprises an interconnected network of porous spheroidal ceramic beads. The microstructure has a total porosity defined as the sum of an open intrabead porosity of the beads and an interbead porosity defined by interstices between the beads in the interconnected network. The microstructure has a bimodal pore size distribution in which an intrabead median pore size of the intrabead porosity is from 1.5 ?m to 4 ?m and an interbead median pore size of the interbead porosity is from 6 ?m to 20 ?m.

Abstract: A particulate filter and method of manufacture. The particulate filter includes intersecting walls that define longitudinally extending channels The intersecting walls comprise a porous ceramic material having a bare microstructure that comprises an interconnected network of porous spheroidal ceramic beads that has an open intrabead porosity within the beads and an interbead porosity defined by interstices between the beads. Catalyst particles are deposited at least partially within the intrabead porosity within the interbead porosity. The bare microstructure has a bimodal pore size distribution in which an intrabead median pore size of the intrabead porosity is less than an interbead median pore size of the interbead porosity. The filter has a trimodal pore size distribution comprising a first peak corresponding to the interbead porosity, a second peak corresponding to the intrabead porosity, and a third peak corresponding to the intrabead porosity as blocked by the catalyst particles.

Abstract: A ceramic precursor mixtures for extrusion and firing into porous ceramics. The ceramic precursor mixtures include ceramic beads and green inorganic shear binder agglomerates. The green inorganic shear binder agglomerates can include inorganic filler particles and a polymeric binder. The green inorganic shear binder agglomerates can deform under an applied shear stress during mixing and/or extrusion such that they are smeared into a plurality of interbead gaps between adjacent ceramic beads or pore former particles. During firing, the smeared green inorganic shear binder agglomerates can sinter and react to form ribbons extending between, and interconnecting adjacent ceramic beads.

Abstract: Disclosed are composite electrodes for use in a solid oxide fuel cell devices. The electrodes are comprised of a sintered mixture of lanthanum strontium ferrite phase and yttria stabilized zirconia phase. The lanthanum strontium ferrite phase has the general formula (LaxSry)i±?(FeaMnbCoc)O3; wherein 1.O?x?0.65; 0.35?y?0.0; x+y=1.0, ?=0-0.1, a+b+c=1, and a>0.6. Also disclosed are methods of making the composite electrodes and solid oxide fuel cell devices comprising same.

Abstract: A solid oxide fuel cell that is capable of increased power density is disclosed. A ceramic electrolyte comprising at least one surface, wherein at least a portion of at least one surface is substantially free of segregated impurities is also disclosed. A solid oxide fuel cell comprising an anode and a cathode, each comprising an active surface, and an electrolyte having a surface, wherein at least a portion of each of the cathode active surface, the anode active surface, and the electrolyte surface are substantially free of segregated impurities is also disclosed. Methods for removing at least a portion of a segregated impurity from a solid oxide fuel cell either prior to or during assembly, or after a period of fuel cell operation are also disclosed.