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Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers

Published by National Renewable Energy Laboratory | Department of Energy | Metadata Last Checked: January 27, 2026 | Last Modified: 2025-11-20T21:02:54Z
Data for "Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers.” 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. The film microstructure and uniformity were investigated by electron microscopy. Membrane electrode assembly testing investigated the impacts of coating method and catalyst layer uniformity on electrolyzer performance and durability. 

Resources

37 resources available

  • Steady-shear rheometry of the 10 wt% IrO2 catalyst ink

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  • Stead-shear rheometry of the 20 wt% IrO2 catalyst ink

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  • Steady-shear rheometry measurements of the 30 wt% IrO2 catalyst ink

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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Gravure Anode Loading: 0.2 mgIr/cm2 Magnification: 19.9kx

    9KX
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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Gravure Anode Loading: 0.2 mgIr/cm2 Magnification: 4.96kx

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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Gravure Anode Loading: 0.4 mgIr/cm2 Magnification: 19.9kx

    9KX
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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Gravure Anode Loading: 0.4 mgIr/cm2 Magnification: 4.96kx

    96KX
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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Gravure Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.11 mgIr/cm2

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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Gravure Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.34 mgIr/cm2

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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Gravure Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.55 mgIr/cm2

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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Slot die Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.08 mgIr/cm2

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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Slot die Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.37 mgIr/cm2

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  • Cross sectional scanning electron microscopy image of anode catalyst layer decal Coating Method: Slot die Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.64 mgIr/cm2

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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Spray Anode Loading: 0.2 mgIr/cm2 Magnification: 19.9kx

    9KX
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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Spray Anode Loading: 0.2 mgIr/cm2 Magnification: 4.96kx

    96KX
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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Spray Anode Loading: 0.4 mgIr/cm2 Magnification: 19.9kx

    9KX
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  • High-angle annular dark field scanning transmission electron microscopy image of MEA after voltage cycling Anode Coating Method: Spray Anode Loading: 0.4 mgIr/cm2 Magnification: 4.96kx

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  • Polarization curve measurements of MEAs as a function of coating method, catalyst ink concentration, and catalyst layer loading. Initial performance only

    INITIAL PERFORMANCE ONLY
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  • Polarization curves for gravure and spray coated catalyst layers measured before and after voltage cycling

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration Catalyst Layer Loading: 0.11 mgIr/cm2 Magnification: 10,000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.11 mgIr/cm2 Magnification: 1000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.11 mgIr/cm2 Magnification: 200x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.34 mgIr/cm2 Magnification: 10,000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.34 mgIr/cm2 Magnification: 1000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.34 mgIr/cm2 Magnification: 200x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.55 mgIr/cm2 Magnification: 10,000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.55 mgIr/cm2 Magnification: 1000x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Gravure Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.55 mgIr/cm2 Magnification: 200x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.08 mgIr/cm2 Magnification: 10000x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.08 mgIr/cm2 Magnification: 1000x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 10 wt% IrO2 Catalyst Layer Loading: 0.08 mgIr/cm2 Magnification: 200x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.37 mgIr/cm2 Magnification: 10,000x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.37 mgIr/cm2 Magnification: 1000x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 20 wt% IrO2 Catalyst Layer Loading: 0.37 mgIr/cm2 Magnification: 200x

    APPLICATION/OCTET-STREAM
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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.64 mgIr/cm2 Magnification: 10,000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.64 mgIr/cm2 Magnification: 1,000x

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  • Top down scanning electron microscopy of catalyst layer decal Coating Method: Slot Die Catalyst Ink Concentration: 30 wt% IrO2 Catalyst Layer Loading: 0.64 mgIr/cm2 Magnification: 200x

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Complete Metadata
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description Data for "Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers.” 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. The film microstructure and uniformity were investigated by electron microscopy. Membrane electrode assembly testing investigated the impacts of coating method and catalyst layer uniformity on electrolyzer performance and durability. 
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    "@type": "dcat:Distribution",
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    "@type": "dcat:Distribution",
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    "@type": "dcat:Distribution",
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    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 10000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD10_10kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 10000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 1000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD10_1kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 1000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 200x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD10_200x.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
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Catalyst Ink Concentration: 10 wt% IrO2
Catalyst Layer Loading: 0.08 mgIr/cm2
Magnification: 200x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 20 wt% IrO2
Catalyst Layer Loading: 0.37 mgIr/cm2
Magnification: 10,000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD20_10kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
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Catalyst Ink Concentration: 20 wt% IrO2
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Magnification: 10,000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 20 wt% IrO2
Catalyst Layer Loading: 0.37 mgIr/cm2
Magnification: 1000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD20_1kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 20 wt% IrO2
Catalyst Layer Loading: 0.37 mgIr/cm2
Magnification: 1000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 20 wt% IrO2
Catalyst Layer Loading: 0.37 mgIr/cm2
Magnification: 200x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD20_200x.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 20 wt% IrO2
Catalyst Layer Loading: 0.37 mgIr/cm2
Magnification: 200x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 10,000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD30_10kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 10,000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 1,000x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD30_1kx.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 1,000x"
  },
  {
    "@type": "dcat:Distribution",
    "title": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 200x",
    "accessURL": "https://data.nrel.gov/system/files/303/1761161607-SD30_200x.tif",
    "mediaType": "application/octet-stream",
    "description": "Top down scanning electron microscopy of catalyst layer decal
Coating Method: Slot Die
Catalyst Ink Concentration: 30 wt% IrO2
Catalyst Layer Loading: 0.64 mgIr/cm2
Magnification: 200x"
  }
]
identifier https://data.openei.org/submissions/8567
issued 2025-11-20T19:48:28Z
keyword 
                                            [
  "electrolysis",
  "roll-to-roll"
]
landingPage https://data.nrel.gov/submissions/303
license https://creativecommons.org/licenses/by/4.0/
modified 2025-11-20T21:02:54Z
programCode 
                                            [
  "019:007"
]
projectNumber AOP 10.2.0.502
projectTitle
publisher 
                                            {
  "name": "National Renewable Energy Laboratory",
  "@type": "org:Organization"
}
title Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers

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