The influence of pore formers on the microstructure of plasma-sprayed NiO-YSZ anodes

► Fabricate SOFC anodes by plasma spraying NiO-YSZ and organic pore-former powders. ► Test HDPE, baking flour, carbon and PEEK powders as pore-formers. ► Evaluate effectiveness of pore-formers by gas flow tests and image analysis. ► Under present plasma spray conditions, flour creates most porosity. ► PEEK exhibits best thermal properties for use as a pore-former for plasma spray.