High manufacturing costs and long-term degradation are the main problems that have become a “bottleneck” and impeded SOFC’s further development. It is well known that a high operating temperature is the major cause that leads to these problems. As such, reducing the operating temperature becomes a hotspot of research. It has been reported that a uniform and dense coating can be prepared by using very low pressure plasma spraying (VLPPS) technology. The current study focuses on VLPPS for application in large-area (~100 × 100 mm) porous metal supported solid oxide fuel cell (MSSOFC), especially for the preparation of the electrolyte. It was found that the densification of the electrolyte was very good, as confirmed by the open-circuit voltage (OCV) of the cell. In the temperature range of 550~750°C, the OCV of the cell stabilized between 1.05 V and 1.1 V. The power density of the cell was also measured.

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