Residual stresses in suspension plasma sprayed electrolytes in metal-supported solid oxide fuel cell half cells

► Yttria-stabilized zirconia (YSZ) electrolyte is made with suspension plasma spray. ► Residual stresses are evaluated via high-temperature X-ray diffractometry. ► Residual stresses in YSZ electrolyte layers are identified to be tensile in nature. ► With increasing temperature the residual stresses are observed to decrease. ► Torch power and stand-off distance have a strong effect on the residual stresses.