Electrostatic spray deposition (BSD) technique was applied to deposit thin, dense yttria stabilized zirconia (YSZ) electrolyte films. The YSZ films were deposited on dense substrates (stainless steel, glass and alumina) and porous NiO-YSZ substrates at 400 deg C. The influence on film morphology of the process parameters such as: salt concentration, polymer additive, deposition time, and substrate nature was studied. A smooth dense film was successfully deposited using the precursor solution based on butyl carbitol and ethanol solvent mixture. A rough porous film was formed when the solvent mixture containing butyl carbitol (40 vol percent), water (40 vol percent), and ethanol (20 vol percent) was sprayed. In this work, we have chosen polyethylene glycol (PEG) polymer as additive to modify the properties of the precursor solutions. The results demonstrated a significant role of the additive on the droplet spreading. The nature of a substrate was not playing a significant role in the film growth.
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