This work demonstrated a highly scalable spray coating process for cathode infiltration with excellent long-term stability for the oxygen reduction reaction. Barium carbonate (BaCO3) nanoparticles have previously demonstrated excellent catalytic activity for the oxygen reduction reaction and were chosen as a model system to be applied by spray coating onto La0.6Sr0.4Co0.2Fe0.8O3-delta (LSCF) and LSCF-SDC (Sm0.2Ce0.8O2-delta) cathode materials. In this work, barium acetate solutions were modified by a surfactant to lower the surface tension and decrease the contact angle on LSCF which is a benefit for the infiltration process. In the LSCF electrode, BaCO3 nano-particles exhibited significant interfacial contact with LSCF particles by the spray coating technique. As a result, the polarization resistance of BaCO3 infiltrated LSCF was reduced from 2.5 to 1.2 Omega cm(2) at 700 degrees C. In addition, commercial full cell SOFCs with BaCO3 infiltrated LSCF-SDC cathodes also demonstrated higher performance due to the reduced cathode resistance. At 750 degrees C, the electrode over potential of the BaCO3 infiltrated cell was much lower than that of baseline cell during long term testing (500 h). The polarization resistance of the BaCO3 infiltrated LSCF-SDC electrode only increased by 1.6% after 500 h. (C) 2017 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.