Co-Cu-SDC mono-layer and Cu-Co-SDC/Cu-YSZ bi-layered anodes were manufactured by air plasma spraying utilizing coarse and fine feedstock powders. The absolute deposition efficiency was determined for each feedstock material to obtain Cu-Co-SDC coatings with 40 vol% of metallic phases and approximately 5 wt% of Co within the metallic phases. The coatings were characterized for porosity, gas permeability, and phase composition. Electrochemical testing was performed to determine the anode performance and long term stability. Cells with mono-layer anodes manufactured of coarse or fine CuO-CoO-SDC feedstock and Cu-Co-SDC/Cu-YSZ bi-layered anodes were tested at 700 degrees C and exhibited power densities of 49 mW cm(-2), 36 mW cm(-2), and 34 mW cm(-2), respectively, and polarization resistances of 2.42 Omega cm(2), 2.23 Omega cm(2), and 1.98 Omega cm(2), respectively. Post-test examination revealed that the Cu undergoes sintering and detachment from surrounding particles during testing, resulting in a decrease of triple phase boundary length and performance degradation. (C) 2012 Elsevier B.V. All rights reserved.