The performance of yttria-stabilized zirconia (YSZ)–samaria-doped ceria (SDC) dual layer electrolyte anode-supported solid oxide fuel cell (AS-SOFC) was investigated. Tape-casting, lamination, and co-sintering of the NiO–YSZ anode followed by wet powder spraying of the SDC buffer layer and BSCF cathode was proposed for fabrication of these cells as an effective means of reducing the number of sintering stages required. The AS-SOFC showed a significant fuel cell performance of ∼1.9 W cm−2 at 800 °C. The fuel cell performance varies significantly with the sintering temperature of the SDC buffer layer. An optimal buffer layer sintering temperature of 1350 °C occurs due to a balance between the YSZ–SDC contact and densification at low sintering temperature and reactions between YSZ and SDC at high sintering temperatures. At high sintering temperatures, the reactions between YSZ and SDC have a detrimental effect on the fuel cell performance resulting in no power at a sintering temperature of 1500 °C.

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