TECHNOLOGY FOCUS - ELECTRONICS - Preferred Components: The electrolyte layer comprises ZrO2 and Y2O3 (20 wt.%).    TECHNOLOGY FOCUS - INORGANIC CHEMISTRY - Preferred Method: The substrate is preheated to a temperature of 150-600 degrees C; is maintained at a temperature of 250-700 degrees C. The precursor solution droplets are injected radially at 90 degrees C relative to the flame axis or axially using atomizing injector nozzle or piezo electric crystal induced liquid injector. Preferred Coating: The coating has a thickness of 1 mu m to 5 mm and there are no vertical cracks. The coating comprises metal oxide, metal carbide, metal nitride and/or metal silicide. Preferred Components: The precursor solution droplets have sufficient mass and velocity to carry the precursor solution droplets into the hot zone. The substrate is selected from metals, coated metals, bond coated metals, ceramics, cermets, stainless steel, titanium, aluminum, nickel superalloys, ceramics, and plastics. The precursor solution droplets comprise a precursor solution comprising a precursor salt selected from carboxylate salt, acetate salt, nitrate salt, chloride salt, alkoxide salt, and butoxide salt of alkali metal, alkaline earth metal, transition metal, rare earth metal and/or their salts. The precursor salt is selected from zirconium nitrate, zirconium carbonate, zirconium acetate, yttrium nitrate, aluminum nitrate, gadolinium acetate, gadolinium nitrate, samarium acetate, samarium nitrate, ytterbium acetate, ytterbium nitrate, nickel nitrate, cerium acetate, lanthanum acetate, iron nitrate, zinc nitrate and/or their salts. The precursor solution droplets have a diameter of 0.5-50 mu m. The thermal spray flame is a plasma spray flame. The precursor solution droplets comprise multiple precursor solutions. The multiple precursor solutions comprise different precursor salts. The thick metal oxide layer comprises Al2O3. The anode layer comprises NiO or La2O3-doped CeO2. The bulk structural material has a thickness of 5 mm to 10 cm, and has no vertical cracks or inter pass boundaries. The metal comprises aluminum, boron, sodium, potassium, lithium, calcium, barium, and magnesium chromium, iron, nickel, zinc, niobium, titanium, zirconium, scandium, yttrium, lanthanum, cerium, gadolinium, praseodymium, neodymium, samarium, terbium and/or ytterbium; stabilized or partially stabilized ceramic. The stabilized ceramic comprises zirconia stabilized with yttria, zirconia stabilized with ceria, zirconia stabilized with scandia, zirconia stabilized with calcia, zirconia stabilized with magnesia, zirconia stabilized with gadolinia, zirconia stabilized with lanthia, zirconia stabilized with samaria, zirconia stabilized with neodymium or zirconia stabilized with ytterbia. EXAMPLE - No suitable example given.