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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Polarization curve measurements of MEAs as a function of coating method, catalyst ink concentration, and catalyst layer loading. Initial performance only
Polarization curves for gravure and spray coated catalyst layers measured before and after voltage cycling
Stead-shear rheometry of the 20 wt% IrO2 catalyst ink
Steady-shear rheometry measurements of the 30 wt% IrO2 catalyst ink
Steady-shear rheometry of the 10 wt% IrO2 catalyst ink
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 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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 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
Citation Formats
TY - DATA
AB - 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.
AU - Mauger
A2 - Ulsh
A3 - Padgett
A4 - Rice
A5 - Lee
A6 - Pylypenko
A7 - Zaccarine
A8 - Jankovic
A9 - Ahmadi
A10 - Batool
A11 - Cullen
A12 - Reeves
DB - Open Energy Data Initiative (OEDI)
DP - Open EI | National Renewable Energy Laboratory
DO -
KW - electrolysis
KW - roll-to-roll
LA - English
DA - 2025/11/20
PY - 2025
PB - National Renewable Energy Laboratory
T1 - Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers
UR - https://data.openei.org/submissions/8567
ER -
Mauger, et al. Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers. National Renewable Energy Laboratory, 20 November, 2025, NREL. https://data.nrel.gov/submissions/303.
Mauger, Ulsh, Padgett, Rice, Lee, Pylypenko, Zaccarine, Jankovic, Ahmadi, Batool, Cullen, & Reeves. (2025). Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers. [Data set]. NREL. National Renewable Energy Laboratory. https://data.nrel.gov/submissions/303
Mauger, Ulsh, Padgett, Rice, Lee, Pylypenko, Zaccarine, Jankovic, Ahmadi, Batool, Cullen, and Reeves. Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers. National Renewable Energy Laboratory, November, 20, 2025. Distributed by NREL. https://data.nrel.gov/submissions/303
@misc{OEDI_Dataset_8567,
title = {Uniformity, Performance, and Durability of Roll-to-Roll-Coated Iridium Oxide Electrolyzer Catalyst Layers},
author = {Mauger and Ulsh and Padgett and Rice and Lee and Pylypenko and Zaccarine and Jankovic and Ahmadi and Batool and Cullen and Reeves},
abstractNote = {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.\ },
url = {https://data.nrel.gov/submissions/303},
year = {2025},
howpublished = {NREL, National Renewable Energy Laboratory, https://data.nrel.gov/submissions/303},
note = {Accessed: 2026-01-02}
}
Details
Data from Nov 20, 2025
Last updated Nov 20, 2025
Submitted Nov 20, 2025
Organization
National Renewable Energy Laboratory
Contact
Scott Mauger
Authors
Mauger
National Renewable Energy LaboratoryUlsh
National Renewable Energy LaboratoryPadgett
National Renewable Energy LaboratoryRice
National Renewable Energy LaboratoryLee
National Renewable Energy LaboratoryPylypenko
Colorado School of MinesZaccarine
Colorado School of MinesJankovic
University of ConnecticutAhmadi
University of ConnecticutBatool
University of ConnecticutCullen
Oak Ridge National LaboratoryReeves
Oak Ridge National LaboratoryOriginal Source
https://data.nrel.gov/submissions/303Research Areas
Keywords
electrolysis, roll-to-rollDOE Project Details
Project Number AOP 10.2.0.502
