A dense yttria-stabilized zirconia (YSZ, 8 mol% Y2O3) film was successfully fabricated by an electrostatic powder-coating process associated with suspension modifying on a porous anode (NiO/YSZ) substrate. The YSZ green powder layer formed by the unmodified process consisted of the loosely packed particles and could not be densified by sintering. After modifying this green layer by a suspension, a dense wet layer was formed that could be sintered at 1450 degreesC. SEM observations showed the film to be dense and approximately 8 mum thick. A single cell with this YSZ electrolyte on Ni/YSZ anode and Ag as cathode was assembled and tested in the temperature range from 550 to 750 degreesC. The open circuit voltage (OCV) and peak power density of the single cell at 750 degreesC was 1.1 V, which is very close to the theoretical value, and 142 mW/cm(2), respectively. The results illustrate that YSZ membranes fabricated by this process are quite dense and gas tight. (C) 2004 Elsevier B.V. All rights reserved.