Scandia-stabilized zirconia electrolyte with improved interlamellar bonding by high-velocity plasma spraying for high performance solid oxide fuel cells

► High-velocity plasma-sprayed ScSZ electrolyte was used directly to SOFC. ► In-flight particle diagnostics are employed to select the optimal spray parameters. ► ScSZ prepared by SAPS exhibits higher gas tightness than conventional APS. ► Electrolyte gas tightness is improved by the increasing of deposition temperature. ► Output power density is increased about 70% with the growth of long columnar crystal.