Publication date: 21st July 2025
Coating Strategies for Integrating Exsolved Nanoparticles onto Metallic Foam
Keywords: Metallic foams, exsolution, powder metallurgy, coating processes, alkaline water electrolysis (AEL)
Porous metallic foams are gaining attention as high-performance catalyst supports in energy applications, offering up to 1000 times the surface area of plain substrates along with excellent electrical conductivity, low pressure drop, and superior thermal and chemical stability. These properties make them ideal platforms for heterogeneous catalysis and electrochemical energy conversion, particularly in alkaline water electrolysis (AEL).
To enhance functionality, ceramic coatings based on perovskites containing exsolvable dopants are applied to the foam surface. Upon thermal treatment in reducing atmosphere, these powders form metallic nanoparticles on the surface of the parent perovskite, that enhance chemical activity and increase the effective surface area of the electrode. Key challenges include achieving strong adhesion, uniform distribution across the foam structure, and a stable interface between coating and substrate.
The quality and strength of the perovskite-to-substrate connection is analyzed using scanning electron microscopy (SEM), with additional insights gained from electrochemical measurements. By bridging material functionality with scalable electrode design, tailored coatings facilitate the industrial implementation of exsolution-based surface technologies in sustainable energy systems.
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