An intermediate temperature solid oxide fuel cell (ITSOFC) based on 8YSZ electrolyte, La(0.6)Sr(0.4)CoO3-delta (LSCo) cathode, and Ni -8YSZ anode coatings were consecutively deposited onto a porous Ni-plate substrate by atmospheric plasma spraying (APS). The spray parameters including current, argon and hydrogen flow rate, and powder feed rate were investigated by an orthogonal experiment to fabricate a thin gas-tight 8YSZ electrolyte coating (80 mum). By proper selection of the spray parameters to decrease the particles velocity and temperature, the sprayed NiO + 8YSZ coating after reducing with hydrogen shows a good electrocatalytic activity for H oxidation. With the same treatment, 100-170 mum dimensions LSCo particle could keep phase structure after spraying. And the deposited LSCo cathode shows a good cathode performance and chemical compatibility with SYSZ electrolyte after operating at 800degreesC for 50h. Outputpower density of the sprayed cell achieved 410 mWcm(-2) at 850degreesC and 260mWcm-2 at 800 degreesC. Electrochemical characterization indicated that IR drop of 8YSZ electrolyte, cathodic polarization, and the contact resistance at LSCo/SYSZ interface were the main factors restricting the cell performance. The results suggested that the use of APS cell allowed the reduction of the operating temperature of the SOFC to below 850degreesC with lower production costs. (C) 2004 Elsevier B.V. All rights reserved.