Abstract: Solid oxide fuel cells that include an alumina substrate as support are described. The alumina substrate supported SOFCs can exhibit desirable electrochemical characteristics including high performance at intermediate temperatures and excellent thermal stability. The alumina substrate support is formed according to a modified phase-inversion process that forms a series of aligned micro-channels extending from a first side to a second opposite side of the support enabling gas distribution between an electrode (e.g., an anode) located on one side of the alumina substrate and the other, opposite side of the alumina substrate.

Abstract: A method for forming tubular solid oxide cells is described. The methods include co-extrusion of an electrode precursor and a sacrificial material to form a multi-layered precursor followed by phase inversion and sintering to remove the sacrificial layer and form an electrode substrate for use in a tubular solid oxide cell. Upon phase inversion and sintering of the precursor, a micro-channel array can be generated in the electrode that is generally perpendicular to the tube surface. The open pored micro-scale geometry of the porous electrode substrate can significantly reduce resistance for fuel/gas transport and increase effective surface area for electrochemical reactions.