Thermal spray processes represent a cost effective and flexible method for the production of functional coatings by using metallurgical, ceramic and cermet materials. Due to the high kinetic energy of the impinging particles, the HVOF (High Velocity Oxygen Fuel) technique is able to produce extremely dense coatings with very low porosity. In this study, several yttria stabilized zirconia (YSZ) powders have been sprayed by HVOF for the fabrication of electrolyte layers for SOFCs (Solid Oxide Fuel Cells) applications. Coatings were characterized regarding their porosity, leak tightness and electrochemical properties. Results were compared to VPS sprayed coatings. The electrochemical behavior of the cells sprayed with the optimized set of parameters was determined applying U(i)-characteristics and impedance spectroscopy. With a destination thickness of about 40 µm, competitive leak tightness of the electrolyte and performance of the cells could be established.