Novel solid oxide fuel cell (SOFC) article and method of manufacture with
improved properties at lower costs. The structural features and methods
involve fabricating an anode (i.e., fuel electrode); applying a cermet
electrolyte, which includes a mixture of ceramic and electrochemically
active substances, and applying a cathodic layer. The cermet electrolyte
containing a small amount of transition metal reduces the thermal
expansion mismatch with the anode, and allows for a graded structure of
the electrochemically active substances across the anode/electrolyte
structure. Under operating conditions, a dense electrolyte and metal
oxide sub-layer exist on the oxidized side (cathode side); while the
other side of the electrolyte (reducing side) is made of a porous
sub-layer containing transition metal. The tailoring of the amounts of
metal present in the anode and the cermet electrolyte allows for greater
power output and enhanced electrochemical performance, while maintaining
the structural integrity and reliability of the SOFC.