This work presents results of design and characterization of metal-supported SOFC using a new type of metallic substrate made of foam Ni-Al alloy compatible with other cell components. Anode nanocomposites NiO/YSZ with graded grain size and porosity were supported via slip casting. A thin (∼ 10 μm) layer of YSZ was supported by MOCVD. Functionally graded layered cathode LSM/LSM+ScCeSZ was supported by electrostatic spray deposition. For button-size cells a power density up to 500 mW/cm2 at 700 °C was obtained using wet H2-air feeds. Cell performance was stable without degradation at short–term tests (∼100h) at 600–800 °C.

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