The (Gd0.1Ce0.9)O2-delta (GDC)-Gd2O3 composite buffer layer was fabricated on yttria stabilized zirconia (YSZ) electrolyte by aerosol deposition for usage as diffusion barrier layer between YSZ and (La0.6Sr0.4)(Co0.2Fe0.8)O3-delta (LSCF)-GDC composite cathode. The deposited composite buffer layer was quite dense in nature and effectively prevented the formation of SrZrO3 and La2Zr2O7 interlayer with low conductivity at the interfaces. The cell's I-V performance was enhanced with an increase in the GDC content in the composite buffer layer. The cell containing composite buffer layer showed maximum power density of up to 1.74 W/cm(2) at 750 degrees C, which was similar to 30% higher than that of the cell containing GDC buffer layer prepared using conventional process. Copyright (C) 2012, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.