Patent ID: 7637967

Claim:
A method for depositing a stepped-gradient fuel electrode onto a fuel cell support, comprising: placing a solid oxide fuel cell support having an air electrode layer and an electrolyte layer into an atmospheric plasma spraying chamber; measuring spray parameters of an atmospheric plasma spray to obtain reactive oxides, conductive metal and graphite phases; spraying said spray parameters onto said solid oxide fuel cell support to produce a plurality of sub-layers defining said stepped-gradient fuel electrode on said solid oxide fuel cell support; and adjusting a hydrogen gas usage of said atmospheric plasma spray; wherein the adjusting of said hydrogen gas usage comprises using a first hydrogen gas level to produce initial sub-layers of said plurality of sub-layers defining a first gradient region and using a second lower hydrogen gas level to produce subsequent sub-layers of said plurality of sub-layers defining a second gradient region; wherein said first gradient region has a greater reactive oxides content than said second gradient region; wherein said first gradient region has a reactive oxides content of 25-50% by weight; and wherein said second gradient region has a reactive oxides content of 10-25% by weight.