Hydrogen separation with dense ceramic membranes is non-galvanic, i.e. it does not require any electrode or an external power supply to drive the separation, and the hydrogen selectivity is almost 100% because the membrane contains no interconnected porosity. In this study, a mixed proton-electron conducting perovslcite made from BaCe(0.9)Y(0.1)O(3-8) (BCYO) was prepared using a solid state reaction, whereas a rapidly solidified Zr-based alloy (RSZ) was obtained via a melt-spinning process at a specified cooling rate. Finally, the BCYO/RSZ composite membrane was successfully fabricated by aerosol deposition (AD) at room temperature. The powders and composite membranes were characterized by high-temperature X-ray diffraction (HTXRD), particle size analysis (PSA), scanning electron microscopy (SEM), and X-ray elemental mapping (XRM). The hydrogen permeability of the dense BCYO/RSZ composite membrane was measured with the change of temperature. Under a pure hydrogen atmosphere at 773 K-1073 K, the BCYO/RSZ composite membrane exhibited higher permeability compared with the sole BCYO membrane over the entire investigated temperature range. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.