Yttria-stabilized zirconia (YSZ) electrolytes were deposited by suspension plasma spraying (SPS) and solution precursor plasma spraying (SPPS). The electrolytes were evaluated for permeability, microstructure, and electrochemical performance. With SPS, three different suspensions were tested to explore the influence of powder size distribution and liquid properties. Electrolytes made from suspensions of a powder with d(50) = 2.6 mu m were more gas-tight than those made from suspensions of a powder with d(50) = 0.6 mu m. A peak open circuit voltage of 1.00 V was measured at 750 degrees C with a cell with an electrolyte made from a suspension of d(50) = 2.6 mu m powder. The use of a flammable suspension liquid was beneficial for improving electrolyte conductivity when using lower energy plasmas, but the choice of liquid was less important when using higher energy plasmas. With SPPS, peak electrolyte conductivities were comparable to the peak conductivities of the SPS electrolytes. However, leak rates through the SPPS electrolytes were higher than those through the electrolytes made from suspensions of d(50) = 2.6 mu m powder. The electrochemical test data on SPPS electrolytes are the first reported in the literature. (C) 2013 Elsevier B.V. All rights reserved.