Patent ID: 8455153

Claim:
A method of forming an anode of a solid oxide fuel cell, comprising the steps of: a) combining a yttria-stabilized-zirconia (YSZ) powder with a NiO/YSZ or NiO powder, wherein particles of the YSZ powder are fused, elongate-shaped YSZ particles having a median particle size, d 50 , in a range of between about 15 microns and about 60 microns and a median particle aspect ratio, AR 50 , in a range of between about 1.2 and 3.0, and particles of the NiO/YSZ or NiO powder are particles having a median particle size, d 50 , in a range of between about 0.5 microns and about 8 microns; and b) sintering the YSZ powder with the NiO/YSZ or NiO powder combination to form the anode component, wherein, upon sintering the combined powders, the fused, elongate-shaped YSZ particles form a microstructural cage of open porosity, wherein the NiO/YSZ or NiO particles are distributed through the open porosity of the cage.