Intermediate temperature solid oxide fuel cells (ITSOFCs) supported by a porous Ni-substrate and based on Sr and Mg doped lanthanum gallate (LSGM) electrolyte, lanthanum strontium cobalt ferrite (LSCF) cathode and nanostructured yttria stabilized zirconia-nickel (YSZ/Ni) cermet anode have been fabricated successfully by atmospheric plasma spraying (APS). From ac impedance analysis, the sprayed YSZ/Ni cermet anode with a novel nanostructure and advantageous triple phase boundaries after hydrogen reduction has a low resistance. It shows a good electrocatalytic activity for hydrogen oxidation reactions. The sprayed LSGM electrolyte with similar to 60 mu m in thickness and similar to 0.054 S cm(-1) conductivity at 800 degrees C shows a good gas tightness and gives an open circuit voltage (OCV) larger than 1 V. The sprayed LSCF cathode with similar to 30 mu m in thickness and similar to 30% porosity has a minimum resistance after being heated at 1000 degrees C for 2 h. This cathode keeps right phase structure and good porous network microstructure for conducting electrons and negative oxygen ions. The APS sprayed cell after being heated at 1000 degrees C for 2 h has a minimum inherent resistance and achieves output power densities of similar to 440 mW cm(-2) at 800 degrees C, similar to 275 mW cm(-2) at 750 degrees C and similar to 170 mW cm(-2) at 700 degrees C. Results from SEM, XRD, ac impedance analysis and I-V-P measurements are presented here. (C) 2008 Elsevier B.V. All rights reserved.