Galvanostatic  Deposition of  Iron Powder from Sulfate Electrolytes: Experimental Analysis and Empirical Modeling

Grigorova, Daniela; Hodjaoglu, Gyunver; Hodzhaoglu, Feyzim

doi:10.22068/ijmse.4281

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‎ 10.22068/ijmse.4281

Galvanostatic Deposition of Iron Powder from Sulfate Electrolytes: Experimental Analysis and Empirical Modeling

Daniela Grigorova

, Gyunver Hodjaoglu

, Feyzim Hodzhaoglu

Abstract: (388 Views)

Producing high-purity iron powders with controlled particle morphology is essential for advanced powder metallurgy, additive manufacturing, and functional materials. However, achieving precise morphological control in environmentally benign, additive-free electrolytes remains challenging. This study systematically investigates the galvanostatic electrodeposition of iron powder from sulfate-based electrolytes containing 10.0 and 50.0 g·L⁻¹ Fe²⁺, focusing on the interplay between current density, pH evolution, deposition efficiency, and particle structure. A clear transition from compact, adherent deposits at low current densities to dendritic, easily detachable powders at higher values was observed. SEM analysis revealed well-defined dendritic aggregates at 7 A·dm⁻² (30–80 μm), whereas highly fragmented, porous agglomerates formed at 10 A·dm⁻², accompanied by fine-scale fragmentation driven by intense hydrogen evolution. XRD confirmed pure α-Fe for current densities up to 7 A·dm⁻², while partial oxidation to Fe₃O₄ occurred at 10 A·dm⁻²; EDX mapping further supported this surface oxidation. The deposited mass increased linearly with current density for both Fe²⁺ concentrations, with regression models yielding R² values above 0.96. Current efficiency decreased at high current densities due to enhanced parasitic reactions. Overall, the results demonstrate that galvanostatic electrodeposition in additive-free sulfate media enables controlled synthesis of iron powders, with tunable morphology and phase purity governed primarily by current density and electrolyte composition.

Keywords: iron powder, galvanostatic electrolysis, sulphate electrolyte, current efficiency, SEM morphology