Dual-layer Ni–YSZ cathode was prepared by the phase-inversion tape casting method.
Pore formation mechanism of the phase-inversion tape casting process was explained.
3D microstructure of the dual-layer Ni–YSZ cathode was first investigated.
Current density of 2.3 A cm− 2 was achieved at 800 °C, 1.5 V and 33% AH.