Redox Power Systems, LLC (Redox) will develop high-throughput, in-line metrology techniques for evaluating protective coatings. The objectives for the effort include identifying key coating and substrate defects that lead to coating failure via detailed characterization methods (e.g., microscopy, XRD, EDS, electrochemistry); assessing capabilities of in-line metrology techniques, e.g., optical profilometry and thermography, to probe these defects; and demonstrating long-term performance of “defect-free” protective coatings, as identified by in-line metrology, in solid oxide fuel cell (SOFC) stack operation. Key outcomes will include identification of key coating and substrate defects leading to coating failure, the capability of in-line metrology techniques to detect these defects, or evidence of them, and demonstration of an optimized in-line metrology methodology that helps extend SOFC stack lifetime.