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

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. 

37 Data Resources
Name Size Type Resource Description History
Rheology - 10 wt% IrO2 Ink 1 KB Document Steady-shear rheometry of the 10 wt% IrO2 catalyst ink
Rheology - 20 wt% IrO2 Ink 1 KB Document Stead-shear rheometry of the 20 wt% IrO2 catalyst ink
Rheology - 30 wt% IrO2 Ink 1 KB Document Steady-shear rheometry measurements of the 30 wt% IrO2 catalyst ink
Membrane Electrode Assembly Polarization Curves - Initial Performance 29 KB Data Polarization curve measurements of MEAs as a function of coating method, catalyst ink concentration, and catalyst layer loading. Initial performance only
Membrane Electrode Assembly Polarization Curves - BOT vs EOT 21 KB Data Polarization curves for gravure and spray coated catalyst layers measured before and after voltage cycling
MEA TEM Cross Section - Gravure 0.2 mgIr/cm2, 4.96kx 1.6 MB Document 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
MEA TEM Cross Section - Gravure 0.2 mgIr/cm2, 19.9kx 1.6 MB Document 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
MEA TEM Cross Section - Gravure 0.4 mgIr/cm2, 4.96kx 1.6 MB Document 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
MEA TEM Cross Section - Gravure 0.4 mgIr/cm2, 19.9kx 1.6 MB Document 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
MEA TEM Cross Section - Spray 0.2 mgIr/cm2, 4.96kx 1.6 MB Document 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
MEA TEM Cross Section - Spray 0.2 mgIr/cm2, 19.9kx 1.6 MB Document 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
MEA TEM Cross Section - Spray 0.4 mgIr/cm2, 4.96kx 1.6 MB Document 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
MEA TEM Cross Section - Spray 0.4 mgIr/cm2, 19.9kx 1.6 MB Document 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
Catalyst Layer Decal SEM Cross Section - Gravure, 10 wt% IrO2 1.1 MB Document 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
Catalyst Layer Decal SEM Cross Section - Gravure, 20 wt% IrO2 1.1 MB Document 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
atalyst Layer Decal SEM Cross Section - Gravure, 30 wt% IrO2 1.1 MB Document 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
Catalyst Layer Decal SEM Cross Section - Slot Die, 10 wt% IrO2 1.1 MB Document 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
Catalyst Layer Decal SEM Cross Section - Slot Die, 20 wt% IrO2 1.1 MB Document 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
Catalyst Layer Decal SEM Cross Section - Slot Die, 30 wt% IrO2 1.1 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 10 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 10 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 10 wt% IrO2, 200x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 20 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 20 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 20 wt% IrO2, 200x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 30 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 30 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Gravure, 30 wt% IrO2, 200x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 10 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 10 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 10 wt% IrO2, 200x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 20 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 20 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 20 wt% IrO2, 200x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 30 wt% IrO2, 1000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 30 wt% IrO2, 10000x 1.3 MB Document 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
Top-Down SEM Catalyst Layer Decal - Slot Die, 30 wt% IrO2, 200x 1.3 MB Document 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
Keywords
electrolysis
roll-to-roll
Submitted
•  Oct  • 07 2025
 
Scott Mauger
303-384-7371
Center 5900
ORCID iD 0000-0003-2787-5029
Author Information
Scott Mauger, National Renewable Energy Laboratory, ORCID iD: 0000-0003-2787-5029
Michael Ulsh, National Renewable Energy Laboratory, ORCID iD: 0000-0003-3725-8032
Elliot Padgett, National Renewable Energy Laboratory
Robin Rice, National Renewable Energy Laboratory
Sanghun Lee, National Renewable Energy Laboratory
Svitlana Pylypenko, Colorado School of Mines
Sarah Zaccarine, Colorado School of Mines
Jasna Jankovic, University of Connecticut
Maryam Ahmadi, University of Connecticut
Mariah Batool, University of Connecticut
David Cullen, Oak Ridge National Laboratory
Kimberly Reeves, Oak Ridge National Laboratory
Cite This Dataset
Mauger, Scott, Michael Ulsh, Elliot Padgett, Robin Rice, Sanghun Lee, Svitlana Pylypenko, Sarah Zaccarine, Jasna Jankovic, Maryam Ahmadi, Mariah Batool, David Cullen, and Kimberly Reeves. 2025. "Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers." NREL Data Catalog. Golden, CO: National Renewable Energy Laboratory. Last updated: November 20, 2025. DOI: 10.7799/3003929.
About This Dataset
303
10.7799/3003929
NREL/JA-5900-96755
Public
11/20/2025
DOE Project
Facilities
Energy Systems Integration Facility (ESIF)
Materials & Chemical Science & Technology (MCS)
Funding Organization
Department of Energy (DOE)
Sponsoring Organization
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Hydrogen Fuel Cell Technologies Office (HFTO)
Research Areas
Hydrogen and Fuel Cells
License
View License
Digital Object Identifier
10.7799/3003929