Uniformity, performance, and durability of roll-to-roll-coated iridium oxide electrolyzer catalyst layers

Mauger, Scott A.; Lee, Sanghun; Rice, Robin; Padgett, Elliot; Zaccarine, Sarah; Ahmadi, Maryam; Batool, Mariah; Reeves, Kimberly S.; Cullen, David A.; Pylypenko, Svitlana; Jankovic, Jasna; Ulsh, Michael

doi:10.1039/D5YA00309A

Title: Uniformity, performance, and durability of roll-to-roll-coated iridium oxide electrolyzer catalyst layers

Journal Article · Mon Feb 16 00:00:00 UTC 2026 · Energy Advances

DOI: https://doi.org/10.1039/D5YA00309A · OSTI ID:3022266

^[1]; Lee, Sanghun ^[1]; Rice, Robin ^[1]; Padgett, Elliot ^[1]; Zaccarine, Sarah ^[2]; Ahmadi, Maryam ^[3]; Batool, Mariah ^[3]; Reeves, Kimberly S. ^[4];

^[4]; Pylypenko, Svitlana ^[2]; Jankovic, Jasna ^[3];

^[1]

National Laboratory of the Rockies (NLR), Golden, CO (United States)
Colorado School of Mines, Golden, CO (United States)
Univ. of Connecticut, Storrs, CT (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)

This work investigates the use of roll-to-roll coating methods for the production of iridium oxide catalyst layers for proton exchange membrane water electrolyzers. Catalyst layers were produced using two coating methods: slot die and gravure. By varying the solids content of the catalyst ink and coating process variables loadings between 0.08 and 0.64 mg_Ir cm⁻² were prepared with relatively high spatial uniformity. However, at loadings below 0.2 mg_Ir cm⁻² microscopy reveals voids in the catalyst layer due to similar length scales of catalyst agglomerates and overall layer thickness. Electrochemical testing shows that these voids do not impact initial membrane electrode assembly performance but lead to increased performance losses after potential cycling compared to spray coated catalyst layers.

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Research Organization:: National Laboratory of the Rockies (NLR), Golden, CO (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Hydrogen Fuel Cell Technologies Office (HFTO)

Grant/Contract Number:: AC36-08GO28308

OSTI ID:: 3022266

Report Number(s):: NLR/JA--5900-96755

Journal Information:: Energy Advances, Journal Name: Energy Advances Journal Issue: 4 Vol. 5; ISSN 2753-1457

Publisher:: Royal Society of ChemistryCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Uniformity, performance, and durability of roll-to-roll-coated iridium oxide electrolyzer catalyst layers

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