Novel strategies based on spray-pyrolysis deposition are proposed to increase the triple-phase boundary (TPB) of La0.8Sr0.2MnO3−δ (LSM) cathodes in contact with yttria-stabilized zirconia (YSZ) electrolyte: (i) nanocrystalline LSM films deposited on as-prepared YSZ surface; (ii) the addition of poly(methyl methacrylate) microspheres as pore formers to further increase the porosity of the film cathodes; and (iii) the deposition of LSM by spray pyrolysis on backbones of Zr0.84Y0.16O1.92 (YSZ), Ce0.9Gd0.1O1.95 (CGO), and Bi1.5Y0.5O3−δ (BYO) previously fixed onto the YSZ. This last method is an alternative to the classical infiltration process with several advantages for large-scale manufacturing of planar solid oxide fuel cells (SOFCs), including easier industrial implementation, shorter preparation time, and low cost. The morphology and electrochemical performance of the electrodes are investigated by scanning electron microscopy and impedance spectroscopy. Very low values of area specific resistance are obtained, ranging from 1.4 Ω·cm2 for LSM films deposited on as-prepared YSZ surface to 0.06 Ω-cm2 for LSM deposited onto BYO backbone at a measured temperature of 650 °C. These electrodes exhibit high performance even after annealing at 950 °C, making them potentially suitable for applications in SOFCs at intermediate temperatures.
