Novel Ni-Al2O3 cermet-supported tubular SOFC cell was fabricated by thermal spraying. Flame-sprayed Al2O3-Ni cermet coating played dual roles of a support tube and an anode current collector. Y2O3-stabilized ZrO2 (YSZ) electrolyte was deposited by atmospheric plasma spraying (APS) to aim at reducing manufacturing cost. The gas tightness of APS YSZ coating was achieved by post-densification process. The influence of YSZ coating thickness on the performance of SOFC test cell was investigated in order to optimize YSZ thickness in terms of open circuit voltage of the cell and YSZ ohmic loss. It was found that the reduction of YSZ thickness from 100 mu m to 40 mu m led to the increase of the maximum output power density from 0.47 W/cm(2) to 0.76 W/cm(2) at 1000 degrees C. Using an APS 4.5YSZ coating of about 40 gin as the electrolyte, the test cell presented a maximum power output density of over 0.88 W/cm(2) at 1030 degrees C. The results indicate that SOFCs with thin YSZ electrolyte require more effective cathode and anode to improve performance. (c) 2006 Elsevier B.V. All rights reserved.