The relationships between the processing parameters, microstructures and electrochemical performance of solid oxide fuel cell (SOFC) components were investigated. The operating regimes (i.e., reducing vs. oxidizing) as well as the elevated temperatures (e.g. 800°C) for their operation introduce several material challenges. Therefore, composite materials are employed to withstand operating conditions while providing sufficient electrochemical performance for fuel cell operation. Analyses on lanthanum-strontium manganite (LSM) - yttria stabilized zirconia (YSZ) compositions (45 vol%-55 vol%) by impedance spectroscopy demonstrated that two competing polarization mechanisms (i.e. charge-exchange and surface adsorption-diffusion of oxygen) limit performance. Optimization of microstructures resulted in total resistances as low as 0.040 Ohm cm². Studies on Ag composites revealed that incorporation of up to 25 vol% oxide particles (LSM and YSZ) with sizes comparable to the Ag grains (~0.5 μm) can minimize the densification and coarsening of the Ag matrix. While the powder based oxide additions increased the stability limit of porous Ag composites from \u3c550°C to 800°C, the use of nanostructured coatings increased the stability limit to 900°C for cathodes and current collectors. Investigations of Ni-YSZ anode microstructures demonstrated that uniform distribution of percolating isometric pores (\u3e5 μm) allows forming desired continuous percolation of all phases (Ni, YSZ and pores) lowering activation polarization below 0.100 Ohm cm² and maintaining significant electrical conductivity (\u3e1000 S/cm). Identification of polarization mechanisms by deconvolution of impedance spectra and tailoring the corresponding microstructures was demonstrated as an effective method for optimization of SOFC components --Abstract, page v
