The paper is principally concerned with strategic investigations based on t
he development of planar supported thin film electrolyte (STEF) configurati
ons for intermediate temperature SOFC applications. A novel and cost effect
ive electrostatic assisted vapour deposition process has been used to depos
it dense YSZ film onto the porous anode substrates. Several approaches were
investigated to deposit a dense and crack-free YSZ film onto the porous an
ode substrate during the fabrication of PEN structure. The use of an amorph
ous YSZ thin film followed by a crystalline YSZ film deposition using the c
ontinuous EAVD process seem to be able to produce a dense and crack-free YS
Z film onto the porous NiO-YSZ substrate with a well defined interface. Ind
ividual dense/porous films and PEN assembly were characterised using XRD, S
EM, and I-V test techniques for structural examination and electrical measu
rements. (C) 1998 published by Elsevier Science B.V. All rights reserved.