The
use of physical vapor deposition methods in the fabrication
of catalyst layers holds promise for enhancing the efficiency of future
carbon capture and utilization processes such as the CO2 reduction reaction (CO2RR). Following that line of research,
we report in this work the application of a sputter gas aggregation
source (SGAS) and a multiple ion cluster source type apparatus, for
the controlled synthesis of CuO
x
nanoparticles
(NPs) atop gas diffusion electrodes. By varying the mass loading,
we achieve control over the balance between methanation and multicarbon
formation in a gas-fed CO2 electrolyzer and obtain peak
CH4 partial current densities of −143 mA cm–2 (mass activity of 7.2 kA/g) with a Faradaic efficiency
(FE) of 48% and multicarbon partial current densities of −231
mA cm–2 at 76% FE (FEC2H4
= 56%). Using atomic force microscopy, electron microscopy,
and quasi in situ X-ray photoelectron spectroscopy,
we trace back the divergence in hydrocarbon selectivity to differences
in NP film morphology and rule out the influence of both the NP size
(3–15 nm, >20 μg cm–2) and in situ oxidation state. We show that the combination of
the O2 flow rate to the aggregation zone during NP growth
and deposition time, which affect the NP production rate and mass
loading, respectively, gives rise to the formation of either densely
packed CuO
x
NPs or rough three-dimensional
networks made from CuO
x
NP building blocks,
which in turn affects the governing CO2RR mechanism. This
study highlights the potential held by SGAS-generated NP films for
future CO2RR catalyst layer optimization and upscaling,
where the NPs’ tunable properties, homogeneity, and the complete
absence of organic capping agents may prove invaluable.