Abstract
A novel porous coating consisting of iridium oxide (IrO2) and tantalum oxide (Ta2O5), modified with multiwalled carbon nanotubes (CNT) was prepared on a titanium (Ti) substrate. The Ta2O5 was obtained by the oxidation of tantalum chloride (TaCl5), and followed by the formation of tantalum carbide (TaC) through the reduction of Ta2O5 with CNT, which generated the intermediate layer of Ta2O5-CNT-TaC. The presence of TaC inhibited the grain growth and refined the particle sizes in the intermediate layer, enhancing the adhesion between the particles, while the introduction of CNT promoted the growth of IrO2 columnar nanocrystal arrayed particles on the active layer, which strengthened the adhesion between the active coating and the substrate. Four characteristic processes involving initiated, continuous, intercrossing and complete coating growths were identified, and further correlated to the electrochemical performance, life and failure behaviors of the coatings. The life of the novel IrO2-Ta2O5-CNT coated Ti electrode was three times longer than that of the conventional IrO2-Ta2O5 coated Ti electrode in sulfuric acid solutions. The electrode failure was mainly caused by the consumption of Ta2O5 at the coating, which damaged the porous structures and destroyed the pore channels.
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