Understanding the Mechanism of Evaporation-Induced Islands during the Formation of Catalyst Layers and Their Influence on the Alkaline Oxidation Evolution Reaction
Authors: Jain Adarsh , Marcks Christian , Chatwani Mohit , Mechler Anna K. , Vinayakumar Vineetha , Chatwani Mohit 
Published: December 2024

Advancements in anode development substantially reduce the cost and enhance the performance of water electrolysis. The strategic configuration of nano-sized catalyst materials on anode supports is a pivotal factor in the expansion of the production of catalyst layers and has a significant influence on their electrochemical performance [1–3]. Therefore, it is essential to understand the structure formation mechanisms during electrode fabrication.
This contribution aims to explore the inherent drying mechanisms in the coating process and their subsequent influence on the morphological evolution of anodes, ultimately establishing a linkage between these morphological changes and electrochemical performance and stability metrics. The initial phase of the study involved a detailed characterization of commercial nickel cobalt oxide nanoparticles via advanced analytical techniques, including transmission electron microscopy and energy-dispersive X-ray spectroscopy [4]. Subsequently, a stable ink was formulated by dispersing the catalyst alongside a binder in a solvent, which was then uniformly applied to a conductive nickel plate utilizing an ultrasonic spray coater. Prior to application, the catalyst inks underwent optimization based on the Hansen solubility parameters of catalyst materials [5, 6] and subsequent visualization of their stability and dispersibility characteristics through transmittogram analysis [7]. The drying process of the coating was conducted at two distinct temperatures, 50 °C and 150 °C, to investigate the effect of temperature on solvent evaporation. Morphological and structural analyses of the anodes were subsequently performed using scanning electron microscopy (SEM), laser scanning microscopy (LSM), and atomic force microscopy (AFM), providing insight into the alterations induced by the drying process.
The analyses conducted in this study elucidate significant modifications in the morphology of the layer structures attributable to variations in drying temperatures as illustrated in Figure 1. Specifically, lower temperature resulted in reduced evaporation rates that facilitated the formation of larger, isolated regions/islands on the anode support. These are indicative of a non-uniform coating distribution. In contrast, a higher temperature promoted rapid evaporation, resulting in a quite homogeneous distribution of smaller islands accompanied by the emergence of voids within the anode layer. Electrochemical analysis revealed that these morphological changes are of vital importance: they govern the wetting behaviour and the dynamics of bubble formation which are important for the electrochemical performance and durability of the catalyst layers. Moreover, the insights gleaned from this study are instrumental in identifying optimal configurations of catalyst layer structures, i.e., features that should be maintained during scale-up.
In conclusion, this study significantly advances the field by revealing novel principles governing the design and optimization of electrode structures for the oxygen evolution reaction. In particular, the complicated relationship between drying temperatures and morphological evolution, which significantly influences electrochemical performance is explained.
References
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Figure 1