NiO-SDC (Samaria-doped ceria) composite powders were synthesized using a urea-combustion technique and Ni-SDC thin films for an intermediate temperature SOFC (IT-SOFC) anode were fabricated by a slurry spin coating method. The results show that the pre-calcination temperatures of the NiO-SDC powders have a significant effect on the microstructure and electrochemical properties of the Ni-SDC anode. A similar to 10 mu m thin film anode with preferred microstructure can be obtained by using the powders pre-calcined at 1000 degrees C. The three-electrode half cell configuration was selected to investigate the electrochemical performance of the thin film on dense yttria-stabilized zirconia (YSZ) substrates. The Ni-SDC anodes exhibited a polarization resistance of 0.11 Omega*cm(-2) together with an overpotential of 33.1 mV under a current density of 200 mA*cm(-2) at 800 degrees C in a 60% N-2 + 40% H-2 atmosphere. (C) 2009 Elsevier B.V. All rights reserved.