Fuel cell components having porous electrodes

An SOFC component, comprising:

• a first electrode layer;
• an electrolyte layer overlying the first electrode layer;
• and
• a second electrode layer overlying the electrolyte layer, the second electrode layer having a bimodal grain size distribution such that the second electrode layer comprises fine grains having an average grain size Gf and coarse grains having an average grain size Gc, wherein Gc/Gf is not less than about 1.5.

A method of forming a SOFC component, comprising:

• forming a first electrode;
• forming an electrolyte overlying the first electrode;
• and
• forming a second electrode overlying the electrolyte, the second electrode comprising powder, the powder comprising agglomerates formed of grains;
• heat treating the first electrode, the electrolyte and the second electrode to form the SOFC component

A method of forming a SOFC component, comprising:

• forming a green first electrode layer;
• forming a green electrolyte layer overlying the first electrode layer;
• and
• forming a green second electrode layer overlying the green electrolyte layer the second electrode layer having a relative green density ρg;
• sintering the first electrode layer, the electrolyte layer and the second electrode layer to densify the layers, the green second electrode layer forming a densified second electrode layer, the densified second electrode layer having a relative sintered density ρs and having porosity, the porosity of the densified second electrode layer being achieved without fugitive pore formers.