Bilayered Y2O3-stabilized ZrO2 (YSZ)/SM2O3-doped CeO2 (SDC) electrolyte films were successfully fabricated on porous NiO-YSZ composite substrates by electrophoretic deposition (EPD) based on electrophoretic filtration followed by co-firing with the substrates. In EPD, positively charged YSZ and SDC powders were deposited directly on the substrates, layer by layer from ethanol-based suspensions. Delamination between YSZ and SDC films was avoided by reducing the SDC films' thickness to ca. 1 mu m. A single cell was constructed on the bilayered electrolyte films composed of ca. 4 mu m-thick YSZ and ca. 1 mu m-thick SDC films. As a cathode in the cell, La0.6Sr0.4Co0.2Fe0.8O3-x (LSCF) was used. Maximum output power densities greater than 0.6 W cm(-2) were obtained at 700 degrees C for the bilayered YSZ/SDC electrolyte cells thus constructed. (c) 2006 Elsevier B.V. All rights reserved.