Periodic Reporting for period 1 - SuperElectro (Superwettability-enhanced Electrocatalysis)
Berichtszeitraum: 2022-05-01 bis 2025-10-31
The transition to climate-neutral and sustainable energy systems depends on our ability to efficiently convert renewable electricity into chemical fuels such as hydrogen or reduced carbon compounds. One of the key limitations in these processes lies at the interface between the electrode and the liquid electrolyte, where gases form and detach during electrolysis. Under normal operation, gas bubbles accumulate on the surface, blocking active sites and disrupting the flow of current. This causes energy losses, uneven performance, and early material degradation, forcing industries to rely on complex mechanical control systems or environmentally persistent chemical additives.
This project set out to overcome these challenges by developing adaptive surface designs that can passively manage how gases form and move along electrode surfaces. Instead of using mechanical stirring or surfactants, the research explored how surface chemistry, texture, and wetting behaviour can be engineered to guide bubble growth, absorption, and release. In doing so, the project aimed to transform the electrode surface from a passive barrier into a self-regulating and energy-efficient component of electrochemical systems.
A particular focus was placed on comparing fluoro-free surfaces, made from environmentally sustainable materials, with high-performance fluoro-optimized surfaces. This comparative approach provided new understanding of how surface molecular structure controls gas repellency, interfacial stability, and durability. In parallel, the project investigated plastrons: microscopic air layers that form on submerged textured surfaces, as potential mediators for smooth gas flow and bubble transport. Together, these insights offer a pathway to design next-generation electrodes coatings that combine high performance with environmental responsibility.
This project set out to overcome these challenges by developing adaptive surface designs that can passively manage how gases form and move along electrode surfaces. Instead of using mechanical stirring or surfactants, the research explored how surface chemistry, texture, and wetting behaviour can be engineered to guide bubble growth, absorption, and release. In doing so, the project aimed to transform the electrode surface from a passive barrier into a self-regulating and energy-efficient component of electrochemical systems.
A particular focus was placed on comparing fluoro-free surfaces, made from environmentally sustainable materials, with high-performance fluoro-optimized surfaces. This comparative approach provided new understanding of how surface molecular structure controls gas repellency, interfacial stability, and durability. In parallel, the project investigated plastrons: microscopic air layers that form on submerged textured surfaces, as potential mediators for smooth gas flow and bubble transport. Together, these insights offer a pathway to design next-generation electrodes coatings that combine high performance with environmental responsibility.
The project combined advanced surface fabrication, imaging, and theoretical modelling to reveal how gases interact with liquid-solid interfaces under real operating conditions.
Researchers developed sustainable surface chemistries that maintained strong water and gas repellency without relying on perfluorinated compounds. These new coatings demonstrated stability and performance comparable to traditional fluorinated materials, proving that environmentally safe alternatives can meet the demands of industrial applications.
At the same time, the project established a new mechanistic picture of how plastrons form, evolve, and break down. Using high-speed microscopy and collaborative experimental and modelling studies, the research quantified how the shape and chemistry of a surface influence bubble motion and gas retention. The results confirmed that plastron-based interfaces can direct gas transport passively, offering a new means to control bubble dynamics in energy devices.
In collaboration with local, European, and international research partners, the project integrated these designed surfaces into prototype electrochemical systems, demonstrating measurable improvements in stability and efficiency. In parallel, new testing methods were developed to study surface durability under corrosive and alkaline environments, providing valuable data for designing electrode coatings that remain functional during long-term operation.
Across its duration, the project produced 12 peer-reviewed publications (11 published), with 7 directly supported by this fellowship, and established lasting collaborations between European and international institutions. The work bridges fundamental wetting science and applied electrochemical engineering, delivering a new platform for surface-controlled gas management.
Researchers developed sustainable surface chemistries that maintained strong water and gas repellency without relying on perfluorinated compounds. These new coatings demonstrated stability and performance comparable to traditional fluorinated materials, proving that environmentally safe alternatives can meet the demands of industrial applications.
At the same time, the project established a new mechanistic picture of how plastrons form, evolve, and break down. Using high-speed microscopy and collaborative experimental and modelling studies, the research quantified how the shape and chemistry of a surface influence bubble motion and gas retention. The results confirmed that plastron-based interfaces can direct gas transport passively, offering a new means to control bubble dynamics in energy devices.
In collaboration with local, European, and international research partners, the project integrated these designed surfaces into prototype electrochemical systems, demonstrating measurable improvements in stability and efficiency. In parallel, new testing methods were developed to study surface durability under corrosive and alkaline environments, providing valuable data for designing electrode coatings that remain functional during long-term operation.
Across its duration, the project produced 12 peer-reviewed publications (11 published), with 7 directly supported by this fellowship, and established lasting collaborations between European and international institutions. The work bridges fundamental wetting science and applied electrochemical engineering, delivering a new platform for surface-controlled gas management.
The results move the field beyond the state of the art by providing the first experimentally validated framework that links wetting properties, interfacial structure, and gas transport behaviour.
Key advances include:
• Demonstration that fluoro-free coatings can achieve high performance in low surface tension liquid environments common to electrochemical processes.
• Establishment of plastron-mediated gas management as a new design principle for electrolyzers and related devices.
• Development of tools and methods towards developing corrosion-resistant and immersion-stable coatings capable of sustaining performance under harsh chemical exposure.
These findings have broad technological implications for sustainable hydrogen production, CO2 conversion, and other gas-involving industrial processes. By showing that interfacial efficiency can be controlled through surface design rather than external energy input, the project opens the way for simpler, more efficient, and environmentally responsible electrochemical systems.
Industrial discussions held during the project highlighted potential applications in energy, materials, and process industries, where control of foaming, bubble formation, and wetting behaviour are key to product performance. The project thus demonstrates how fundamental research on interfaces can translate directly into new concepts for green manufacturing and sustainable materials engineering.
Key advances include:
• Demonstration that fluoro-free coatings can achieve high performance in low surface tension liquid environments common to electrochemical processes.
• Establishment of plastron-mediated gas management as a new design principle for electrolyzers and related devices.
• Development of tools and methods towards developing corrosion-resistant and immersion-stable coatings capable of sustaining performance under harsh chemical exposure.
These findings have broad technological implications for sustainable hydrogen production, CO2 conversion, and other gas-involving industrial processes. By showing that interfacial efficiency can be controlled through surface design rather than external energy input, the project opens the way for simpler, more efficient, and environmentally responsible electrochemical systems.
Industrial discussions held during the project highlighted potential applications in energy, materials, and process industries, where control of foaming, bubble formation, and wetting behaviour are key to product performance. The project thus demonstrates how fundamental research on interfaces can translate directly into new concepts for green manufacturing and sustainable materials engineering.