Yttria stabilized zirconia (YSZ) has widely been used as an electrolyte in solid oxide fuel cell (SOFC) stacks. The microstructure and properties of YSZ related to the fabrication process are discussed in this paper. For the named two-step sintering process, uniform and hexagonal grains with a size of 1-4 mu m were obtained from the adobe following tape calendaring (TCL). Elliptical and hexagonal grains with a size of 0.4-3 mu m were obtained from the adobe of tape casting (TCS) using the three-step process. The electrical conductivities of YSZ with different grain sizes were measured via the four-probe DC technique and grain conductivities and grain boundary conductivities of YSZ were investigated by impedance spectroscopy. YSZ electrolytes with a grain size of 0.1-0.4 mu m had the highest electrical conductivity in the range of 500-1000 degrees C, especially at medium and low temperatures 550-800 degrees C. As the YSZ grain size becomes small, the thickness of the intergranular region decreased greatly. The YSZ electrolytes with sub-micrometer grain sizes, high ion conductivity and low sintering temperatures are important to the electrode- supported SOFC, on which the dense YSZ electrolyte films are optimized at 10 mu m. (c) 2006 Elsevier B.V. All rights reserved.