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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

IHS-60 Stored Energy Analysis

The IHS-60 consists of a General Purpose Heat Source (GPHS) Fueled Clad (FC) that has been hot isostatically pressed to eliminate the gap between the iridium clad and the fuel pellet, thus preventing differential motion between the pellet and the clad in shock and vibration environments. The vented FC is enclosed within a Molybdenum barrier comprising the liner body and the lower support member. The slip- t Molybdenum liner members serve as a mechanical barrier to plutonia contact of the tantalum alloy (T-111) strength member in the event the iridium clad should fail. The slip- t liner is not a barrier to gaseous transport, so a tantalum getter is installed near the vent region of the FC to preclude potential oxygen transport to the T-111 interior surface. The T-111 strength member encloses the Molybdenum liner assembly and provides for both helium gas retention and isotope fuel containment under impact and external pressure environments. It is surrounded by an outer clad of Hastelloy-S which protects the strength member from external oxidation and corrosive sources during nominal operation and in the event of off-nominal operation or accidents. Both the strength member and outer clad parts are closed with seal welds. The strength member and outer clad are the primary containment members of the 60-Watt IHS. The iridium clad contains the fuel pellet during nominal operation and mild accident environments, but it is not considered to be a primary containment member.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Report on ISR-1 High-Altitude Balloon Flight

To test small technologies at lower cost for space science applications, LANL has developed a small high altitude balloon payload that could, in the future, be regularly and inexpensively launched from LANL. A neutron detector, NEMO, was integrated to evaluate its performance in a space-like mixed-radiation environment and collect neutron data in the atmosphere. In collaboration with EES-14, a high-altitude balloon payload was launched from LANL Technical Area 51 on February 27, 2023 and April 17, 2023. For real-time geolocation, a SAM-M8Q M8 GNSS module was used to get position and time, and an Iridium RockBLOCK 9603 was used to communicate with the ground using the Iridium satellite fleet. These modules were all controlled using an Iteaduino Mega microcontroller board. Finally, a High Altitude Science Eagle Flight Computer with a temperature pressure sensor ran independently, writing data to an SD card. All of these modules were powered by a 5 mAh lithium polymer battery. The battery was attached to the bottom of the payload while the remaining electronics were embedded in the underside of the top of the payload. These modules were wired as seen in Figure 1-2. The Iteaduino Mega microcontroller board was programmed to use the RockBLOCK to send a message once every 10 minutes containing neutron and GPS data read off the NEMO and SAM M8Q, respectively. Once the message send attempt finished, the RockBLOCK would be slept for the rest of the 10 minute interval. The Eagle Flight Computer ran continuously throughout the flight, taking data every 6 seconds. The RockBLOCK message data was set up to be delivered from the Iridium satellite fleet to a website, where it was stored and parsed to create live maps and plots for analysis and balloon retrieval. The RockBLOCK message data was additionally configured to be sent to an email as a fail-safe. The payload was ground-tested successfully for over 50 hours, with multiple revisions occurring to best prepare for conditions at altitude and improve the software and firmware to fix any issues that cropped up with the data pipeline. Additional to the balloon payload, the flight had an attached iMet-4 radiosonde and Garmin T5 GPS Dog Collar. The radiosonde provided GPS and meteorological data. The T5 dog collar is used along with a Garmin Astro 430 to track the balloon at a range of up to 9 miles for retrieval. The balloon itself was initially a 1600 g meteorological balloon with an attached High Altitude Science parachute, both of which can be seen in Figure 1-3. After the first flight, the EES team swapped to a Rocketman parachute.

42 ENGINEERING↗
NASA NTRS1980

Extraterrestrial cause for the Cretaceous-Tertiary extinction

Direct physical evidence is presented for an unusual event at exactly the time of extinctions in the planktonic realm. Deep-sea limestones exposed in Italy, Denmark, and New Zealand indicate iridium increases of about 30, 160, and 20 times, respectively, above the background level at precisely the time of the Cretaceous-Tertiary extinctions, 65 million years ago. Reasons are given that this iridium is of extraterrestrial origin, but did not come from a nearby supernova. A hypothesis is set forth which accounts for the extinctions and the iridium observations. One prediction of this hypothesis is verified, that the chemical composition of the boundary clay, which is thought to come from the stratospheric dust, is markedly different from that of clay mixed with the chemically similar Cretaceous and Tertiary limestones.

Alvarez, L. W.↗
NASA NTRS1986

High-temperature oxidation of a rapidly solidified amorphous Ta-Ir alloy

The oxidation products formed at 500 and 700 C on an amorphous Ta-44.5 at. pct Ir alloy in an Ar-0.1 percent O2 gas mixture were characterized using SEM, XRD, EPMA, TEM, STEM, AES, and XPS. Initially, a thin (3-4 nm) layer of Ta2O5 formed at the surface of the alloy. Continued growth of the Ta2O5, which occurred very rapidly, involved diffusion of oxygen anions from the Ta2O5/gas interface to the alloy/Ta2O5 interface, where tantalum was selectively oxidized. Because the oxide grew more quickly than iridium could diffuse back into the alloy, the iridium coalesced into platelets of crystalline iridium-rich alloy that were oriented approximately parallel to the oxide/alloy interface, and which became embedded in a matrix of Ta2O5. The unoxidized core remained in the glassy state. The oxidation process and/or the dissolution of oxygen into the unoxidized alloy caused the alloy to become embrittled.

Cotell, Catherine M.↗
NASA NTRS1988

Geochemistry of K/T boundaries in India and contributions of Deccan volcanism

Three possible Cretaceous/Tertiary (K/T) boundary sections in the Indian subcontinent were studied for their geochemical and fossil characteristics. These include two marine sections of Meghalaya and Zanskar and one continental section of Nagpur. The Um Sohryngkew river section of Meghalaya shows a high iridium, osmium, iron, cobalt, nickel and chromium concentration in a 1.5 cm thick limonitic layer about 30 cm below the planktonic Cretaceous-Palaeocene boundary identified by the characteristic fossils. The Bottaccione and Contessa sections at Gubbio were also analyzed for these elements. The geochemical pattern at the boundary at the Um Sohryngkew river and Gubbio sections are similar but the peak concentrations and the enrichment factors are different. The biological boundary is not as sharp as the geochemical boundary and the extinction appears to be a prolonged process. The Zanskar section shows, in general, similar concentration of the siderophile, lithophile and rare earth elements but no evidence of enrichment of siderophiles has so far been observed. The Takli section is a shallow inter-trappean deposit within the Deccan province, sandwiched between flow 1 and flow 2. The geochemical stratigraphy of the inter-trappeans is presented. The various horizons of ash, clay and marl show concentration of Fe and Co, generally lower than the adjacent basalts. Two horizons of slight enrichment of iridium are found within the ash layers, one near the contact of flow 1 and other near the contact of flow 2, where iridium occurs at 170 and 260 pg/g. These levels are lower by a factor of 30 compared to Ir concentration in the K/T boundary in Meghalaya section. If the enhanced level of some elements in a few horizons of the ash layer are considered as volcanic contribution by some fractionation processes than the only elements for which it occurs are REE, Ir and possibly Cr.

Bhandari, N.↗
NASA NTRS1988

Search for the Tunguska event in the Antarctic snow

The Tunguska explosion in 1908 is supposed to have been produced by the impact of a small celestial body. The absence of any identifiable crater together with the huge energy released by the event suggest that the impactor exploded in midair and that its material was widely spread over the Earth. The short term contribution of such exceptional events to the total accretion rate of extraterrestrial material by the Earth could be significant. Samples were chosen in a core electromechanically drilled in 1984 near South Pole Station. There, the low temperatures, preventing melting all year long, and the nearly regular snow fall rate provide good conditions for a reliable continuous record of any infalling material. In many samples Ir was below the detection limit of the instrumentation. The iridium infall averaged over 45 samples is given. In a few samples the iridium content is significantly higher than the average: the frequency and amplitude of such fluctuations can be explained by the presence on some filters of finite size cosmic particles. No significant systematic increase above the average level is observed in the part of the core corresponding to the Tunguska event. The two major results of this study are: (1) The presence of Tunguska explosion debris in the Antarctic snow is not confirmed; and (2) The estimate of the average iridium infall, is an order of magnitude lower than the Ganapathy's background but is close to the values measured in Antarctic snow and atmospheric samples by Takahashi et al. The results are also consistent with the flux of micrometeoroids deduced from optical and radar observations or derived from the study of Greenland cosmic dust collection but are lower than the flux at mid-latitude measured in paleocene-oligocene sediments from the central part of the Pacific Ocean.

Rocchia, R.↗
NASA NTRS1992

Advanced liquid rockets

A program to substitute iridium coated rhenium for silicide coated niobium in thrust chamber fabrications is reviewed. The life limiting phenomena in each of these material systems is also reviewed. Coating cracking and spalling is not a problem with iridium-coated rhenium as in silicide-coated niobium. Use of the new material system enables an 800 K increase in thruster operating temperature from around 1700 K for niobium to 2500 K for rhenium. Specific impulse iridium-coated rhenium rockets is nominally 20 seconds higher than comparable niobium rockets in the 22 N class and nominally 10 seconds higher in the 440 N class.

Schneider, Steven J.↗
NASA NTRS1993

Testing and evaluation of oxide-coated iridium/rhenium chambers

Iridium-coated rhenium provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase iridium/rhenium rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated iridium/rhenium, 22 N rocket chambers were tested on gaseous hydrogen/gaseous oxygen propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia or zirconia. Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of zirconia infiltrated with sol gel hafnia. The other chamber had a coating composed of an iridium/oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. The iridium/oxide composite coated chamber included testing for over 29 minutes at mixture ratio 16. The thicker-walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner-walled coatings did not experience the macrocracking and chipping of the chambers seen with the thick, monolithic coatings. However, burnthroughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stochiometric. The burn-throughs were probably the result of oxygen-diffusion through the oxide coating that allowed the underlying iridium and rhenium layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗
NASA NTRS1998

High temperature thrust chamber for spacecraft

A high temperature thrust chamber for spacecraft (20) is provided herein. The high temperature thrust chamber comprises a hollow body member (12) having an outer surface and an internal surface (16) defining the high temperature chamber (10). The body member (12) is made substantially of rhenium. An alloy (18) consisting of iridium and at least alloying metal selected of the group consisting of rhodium, platinum and palladium is deposited on at least a portion of the internal surface (16) of the body member (12). The iridium and the alloying metal are electrodeposited onto the body member (12). A HIP cycle is performed upon the body member (12) to cause the coating of iridium and the alloying metal to form the alloy (18) which protects the body member (12) from oxidation.

Chazen, Melvin L.↗
NASA NTRS2010

Roles of Thin Film Stress in Making Extremely Lightweight X-Ray Optics

X-ray optics typically must be coated with one of the noble metals, gold, platinum, or iridium, to enhance their photon collection area. In general, iridium is preferred to the other two because it generates the highest X-ray reflectivity in the I to 10 keV band. Unfortunately, iridium films typically have also the highest stress that can severely degrade the optical figure of the mirror substrate, resulting in a poorer image quality. In this paper we will report our work in understanding this stress and our method to counterbalance it. In particular we will also report on potential ways of using this stress to improve the substrate's optical figure, turning a bug into a desirable feature. This work is done in the context of developing an enabling technology for the International X-ray Observatory which is a collaborative mission of NASA, ESA, and JAXA, and expected to be launched into an L2 orbit in 2021.

Zhang, William W.↗
NASA NTRS2010

Corrosion-Resistant Container for Molten-Material Processing

In a carbothermal process, gaseous methane is passed over molten regolith, which is heated past its melting point to a temperature in excess of 1,625 C. At this temperature, materials in contact with the molten regolith (or regolith simulant) corrode and lose their structural properties. As a result, fabricating a crucible to hold the molten material and providing a method of contact heating have been problematic. Alternative containment approaches use a large crucible and limit the heat zone of the material being processed, which is inefficient because of volume and mass constraints. Alternative heating approaches use non-contact heating, such as by laser or concentrated solar energy, which can be inefficient in transferring heat and thus require higher power heat sources to accomplish processing. The innovation is a combination of materials, with a substrate material having high structural strength and stiffness and high-temperature capability, and a coating material with a high corrosion resistance and high-temperature capability. The material developed is a molybdenum substrate with an iridium coating. Creating the containment crucible or heater jacket using this material combination requires only that the molybdenum, which is easily processed by conventional methods such as milling, electric discharge machining, or forming and brazing, be fabricated into an appropriate shape, and that the iridium coating be applied to any surfaces that may come in contact with the corrosive molten material. In one engineering application, the molybdenum was fashioned into a container for a heat pipe. Since only the end of the heat pipe is used to heat the regolith, the container has a narrowing end with a nipple in which the heat pipe is snugly fit, and the external area of this nipple, which contacts the regolith to transfer heat into it, is coated with iridium. At the time of this reporting, no single material has been found that can perform the functions of this combination of materials, and other combinations of materials have not proven to be survivable to the corrosiveness of this environment. High-temperature processing of materials with similar constituencies as lunar regolith is fairly common. The carbo-thermal process is commonly used to make metallurgical-grade silicon for the semiconductor and solar-cell industries.

Stern, Theodore G.↗
NASA NTRS2006

Alpha-Voltaic Sources Using Liquid Ga as Conversion Medium

A family of proposed miniature sources of power would exploit the direct conversion of the kinetic energy of alpha particles into electricity. In addition to having long operational lives, these sources are expected to operate with energy-conversion efficiencies from 70 to 90 percent. A power source as proposed (see figure) would be an electrolytic cell in which liquid gallium would serve as both an electrolyte and an energy-conversion medium. The cell would contain an iridium cathode and a zirconium anode. The alpha particles, each with a kinetic energy approx.5.8 MeV, would be emitted by radioactive decay of Cm-244, which has a half-life of 18 years. The Cm-244 source would be positioned so that the a particles would enter the liquid gallium, where their kinetic energy would be dissipated mostly through ionization of Ga atoms, creating Ga(+) ions and free electrons. The electrons would be collected by iridium cathode, and the Ga(+) ions would be neutralized at the zirconium cathode by electrons returning after flowing through an external circuit. Gallium is a candidate for use as the electrolyte and the energy-conversion medium because in the liquid state it is a semimetal: its electrical conductivity is greater than that of a typical semiconductor but small in comparison with the conductivities of metals. Consequently, in liquid gallium, electrons and Ga(+) can exist without immediate recombination and can be moved by electric fields. It is expected that electric fields, resulting at least partly from the difference between the work functions of the electrode metals, would move the electrons and ions to their respective electrodes. The open-circuit potential of the cell is expected to be 1.62 V - equal to the difference between the work functions of iridium and zirconium. Unlike in a solid-state energy conversion medium, the impingement of energetic a particles would not give rise to displacement damage in the liquid gallium. Hence, the cell should have a long life, limited only by the half-life of Cm-244. A cell having a volume less than 25 cu mm, containing 1 curie of Cm-244 (the curie is a unit of radioactivity equal to 3.7 10(exp 10) disintegrations per second) is expected to deliver a current between 7 and 12 mA, which, at the expected open-circuit potential, would provide a power in the approximate range of 11 to 20 mW.

Patel, Jagdish U.↗
NASA NTRS2011

Engineering and Technology Challenges for Active Debris Removal

After more than fifty years of space activities, the near-Earth environment is polluted with man-made orbital debris. The collision between Cosmos 2251 and the operational Iridium 33 in 2009 signaled a potential collision cascade effect, also known as the "Kessler Syndrome", in the environment. Various modelling studies have suggested that the commonly-adopted mitigation measures will not be sufficient to stabilize the future debris population. Active debris removal must be considered to remediate the environment. This paper summarizes the key issues associated with debris removal and describes the technology and engineering challenges to move forward. Fifty-four years after the launch of Sputnik 1, satellites have become an integral part of human society. Unfortunately, the ongoing space activities have left behind an undesirable byproduct orbital debris. This environment problem is threatening the current and future space activities. On average, two Shuttle window panels are replaced after every mission due to damage by micrometeoroid or orbital debris impacts. More than 100 collision avoidance maneuvers were conducted by satellite operators in 2010 to reduce the impact risks of their satellites with respect to objects in the U.S. Space Surveillance Network (SSN) catalog. Of the four known accident collisions between objects in the SSN catalog, the last one, collision between Cosmos 2251 and the operational Iridium 33 in 2009, was the most significant. It was the first ever accidental catastrophic destruction of an operational satellite by another satellite. It also signaled the potential collision cascade effect in the environment, commonly known as the "Kessler Syndrome," predicted by Kessler and Cour-Palais in 1978 [1]. Figure 1 shows the historical increase of objects in the SSN catalog. The majority of the catalog objects are 10 cm and larger. As of April 2011, the total objects tracked by the SSN sensors were more than 22,000. However, approximately 6000 of them had yet to be fully processed and entered into the catalog. This population had been dominated by fragmentation debris throughout history. Before the anti-satellite test (ASAT) conducted by China in 2007, the fragmentation debris were almost all explosion fragments. After the ASAT test and the collision between Iridium 33 and Cosmos 2251, the ratio of collision fragments to explosion fragments was about one-to-one. It is expected that accidental collision fragments will further dominate the environment in the future.

Liou, Jer-Chyi↗
NASA NTRS2003

Oxide Protective Coats for Ir/Re Rocket Combustion Chambers

An improved material system has been developed for rocket engine combustion chambers for burning oxygen/ hydrogen mixtures or novel monopropellants, which are highly oxidizing at operating temperatures. The baseline for developing the improved material system is a prior iridium/rhenium system for chambers burning nitrogen tetroxide/monomethyl hydrazine mixtures, which are less oxidizing. The baseline combustion chamber comprises an outer layer of rhenium that provides structural support, plus an inner layer of iridium that acts as a barrier to oxidation of the rhenium. In the improved material system, the layer of iridium is thin and is coated with a thermal fatigue-resistant refractory oxide (specifically, hafnium oxide) that serves partly as a thermal barrier to decrease the temperature and thus the rate of oxidation of the rhenium. The oxide layer also acts as a barrier against the transport of oxidizing species to the surface of the iridium. Tests in which various oxygen/hydrogen mixtures were burned in iridium/rhenium combustion chambers lined with hafnium oxide showed that the operational lifetimes of combustion chambers of the improved material system are an order of magnitude greater than those of the baseline combustion chambers.

Fortini, Arthur↗
NASA NTRS2015

SOAREX-8 Suborbital Experiments 2015 - A New Paradigm for Small Spacecraft Communication

In 2015 NASA plans to launch a payload to 280 Km altitude on a sounding rocket from the Wallops Flight Facility. This payload will contain several novel technologies that work together to demonstrate methodologies for space sample return missions and for nanosatellite communications in general. The payload will deploy and test an Exo-Brake, which slows the payload aerodynamically, providing eventual de-orbit and recovery of future ISS samples through a Small Payload Quick Return project. In addition, this flight addresses future Mars mission entry technology, space-to-space communications using the Iridium Short Messaging Service (SMS), GPS tracking, and wireless sensors using the ZigBee protocol. SOAREX-8 is being assembled and tested at Ames Research Center (ARC) and the NASA Engineering and Safety Center (NESC) is funding sensor and communications work. Open source Arduino technology and software are used for system control. The ZigBee modules used are XBee units that connect analog sensors for temperature, air pressure and acceleration measurement wirelessly to the payload telemetry system. Our team is developing methods for power distribution and module mounting, along with software for sensor integration, data assembly and downlink. We have demonstrated relaying telemetry to the ground using the Iridium satellite constellation on a previous flight, but the upcoming flight will be the first time we integrate useful flight test data from a ZigBee wireless sensor network. Wireless sensor data will measure the aerodynamic efficacy of the Exo-Brake permitting further on orbit flight tests of improved designs. The Exo-Brake is 5 sq m in area and will be stored in a container and deployed during ascent once the payload is jettisoned from the launch vehicle. We intend to further refine the hardware and continue testing on balloon launches, future sounding rocket flights and on nanosatellite missions. The use of standards-based and open source hardware/software has allowed for this project to be completed with a very modest budget and a challenging schedule. There is a wealth of hardware and software available for both the Arduino platform and the XBee, all low-cost or open-source. Along with the Exo-Brake hardware and deployment discussion, this paper will describe in detail the system architecture emphasizing the successful use of open source hardware and software to minimize effort and cost. Testing procedures, radio frequency interference (RFI) mitigation, success criteria and expected results will also be discussed. The use of Iridium short messaging capability for space-to-space links, standards-based wireless sensor networks, and other innovative communications technology are also presented.

aerobrake↗
DOE OSTI2020

Perovskite-Type Solid Solution Nano-Electrocatalysts Enable Simultaneously Enhanced Activity and Stability for Oxygen Evolution

A trade-off between catalytic activity and structural stability generally exists in oxygen evolution electrocatalysis, especially in acidic environment. This dilemma limits the development of higher-performance electrocatalysts that are required by next-generation electrochemical technologies. In this work it is demonstrated that the inverse catalytic activity–structural stability relation can be broken by alloying catalytically inert strontium zirconate with the other catalytically active perovskite, strontium iridate. This strategy results in an alloyed perovskite electrocatalyst with simultaneously improved iridium mass activity and structural stability, by about five times, for the oxygen evolution reaction under acidic conditions. The experimental and theoretical results suggest that the alloying strategy generates multiple positive effects, mainly including the reduction of catalyst size, the decrease of catalyst covalency, and the weakening of surface oxygen-binding ability. The synergistic optimization of bulk and surface properties, as a result, enhances the intrinsic activity and availability of surface iridium sites, whilst significantly inhibiting the surface cation corrosion during electrocatalysis.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Stochastic generation of electrolyzer anode catalyst layers

Here, we introduce a stochastic methodology to reproduce the complex pore structure observed in commercial iridium catalyst layers. This method preserves the α pore (pores smaller than 250 nm) and β pore (pores greater than or equal to 250 nm) regions of the catalyst layer. The morphology of the generated materials was validated by comparing the pore size distributions of generated materials against those obtained from commercial materials imaged using x-ray nano computed tomography. We further demonstrate that the pore size distributions of the generated materials are statistically indistinguishable from the imaged catalyst layers, indicating that the stochastic methodology is capable of accurately reproducing catalyst layer morphology. Pore network modelling was conducted on the generated catalyst materials to simulate single-phase permeability, electrical conductivity, and ionic conductivity, and these properties were found to be within experimentally measured ranges for electrolyzer catalyst layers. Additionally, simulations were performed on the generated materials with varying ionomer and iridium catalyst loadings. As the ionomer loading is added, proton conductivity increases exponentially, which demonstrates the importance of optimizing ionomer loading, considering that these effects will be exacerbated in the hydration and temperature conditions of operating electrolyzers. The stochastic material generation method presented in this work is a powerful tool for the development of novel low loading catalyst layers, where the effect of various structural parameters on electrolyzer performance characteristics can be explored.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Supported Oxygen Evolution Catalysts by Design: Toward Lower Precious Metal Loading and Improved Conductivity in Proton Exchange Membrane Water Electrolyzers

Reducing the precious metal content of water oxidation catalysts for proton-exchange-membrane water electrolyzers remains a critical barrier to their large-scale deployment. Herein, we present an engineered architecture for supported iridium catalysts, which enables decreased precious metal content and improved activity and conductivity. The improvement in performance at lower precious metal loading is realized by the deposition of a conformal layer of platinum nanoparticles on titanium dioxide (TiO 2 ) using a facile photoreduction method to prepare conductive layer coated supports (CCSs). Platinum nanoparticles are homogeneously dispersed on TiO 2 , and the conductivity of the subsequent catalysts with 39 wt % precious group metal loadings is significantly higher than the commercial 75 wt % loaded IrO 2 -TiO 2 catalysts. The conformal conductive layer also maintains an enhanced conductivity and electrochemical activity upon thermal annealing when compared to catalysts without the conductive layer and nonconformal heterogeneous conductive layer. The iridium mass activity from half-cell studies shows a 141% improvement for CCS supported catalysts at 42% lower loadings compared to the commercial catalysts. The conductive layer also improves the single cell electrolyzer performance at a similar catalyst loading in comparison to a commercial state-of-the-art catalyst. Here, we correlate the physical properties of the engineered catalysts with their electrochemical performance in electrolyzers to understand structure-activity relationships, and we anticipate further performance improvements upon synthesis and materials optimizations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗