In this study, the large‐scale mold for compression molding process is prepared and a compression load of 200 ton is applied to form a porous alloy specimen with dimension of 11×11×1.2 cm. The pyrolyzable filler is used in the period of manufacturing processes in order to produce porous interconnected networks of iron (Fe)‐containing chromium (Cr)‐based alloy. The specimens are sintered in hydrogen at the temperature of 1350°C to obtain porous alloy substrate. The flexural strength of porous alloy supporting component is measured in this work. The strength of porous alloy substrate (sintered at 1350°C) in three‐point flexure at 25°C and 750°C are 158 MPa and 63 MPa, respectively. Metal‐supported solid oxide fuel cells (MS‐SOFCs) are fabricated by thermal plasma spraying technique and double layer formed of YSZ‐NiO, GDC‐NiO composite anode, a diffusion barrier layer (Ce0.55La0.45O2‐δ‐NiO, LDC‐NiO), electrolyte (La0.8Sr0.2Ga0.8Mg0.2O3‐δ, LSGM) and cathode (Sm0.5Sr0.5CoO3‐δ, SSC) functional layers are deposited onto porous alloy substrate. The 10×10 cm2 MS‐SOFC with effective electrode area of 81 cmcm2 shows the open circuit voltages is 1.03 V at 750°C. The measured maximum output power densities (@0.68V) of this cell has reached 411 mW/cm2 at 750°C by using hydrogen as fuel and air as oxidant.
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