Patent ID: 8617762

Claim:
A method for processing a ceramic electrolyte suitable for use in a fuel cell, the method comprising the steps of: situating a ceramic electrolyte layer over an anode layer, wherein the electrolyte layer comprises a top surface, a bottom surface, and a plurality of microcracks extending at least partially between the two surfaces, such that the bottom surface of the electrolyte layer is adjacent to the anode layer; and pre-treating the ceramic electrolyte layer prior to operation of the fuel cell, by subjecting the ceramic electrolyte layer to a stress sufficient to initiate microcracks in the electrolyte layer, by: exposing the top surface of the electrolyte layer to an oxidizing atmosphere and the bottom surface of the electrolyte layer to a reducing atmosphere; and heating the electrolyte layer, wherein the stress causes a substantial increase in the number of microcracks, or in the average size of the microcracks, or in both the number of microcracks and their average size; and then infiltrating the pre-treated ceramic electrolyte layer.