Automated rotating cathode system design and material optimization for zero-residue dendritic copper powder production

This study introduces an automated rotating cathode roller electrolysis system designed to eliminate cathode residue and ensure consistent production of high-quality dendritic copper powder (DCP). We systematically evaluated Cu, Mo, 316 L stainless steel (316 L), Ti, and Ta cathodes to unravel their impact on DCP morphology, residue accumulation, and energy efficiency. After 10 deposition cycles (10 min/cycle), Cu cathodes accumulated severe residue (89.62 g m −2 ), causing particle coarsening, a 51 % increase in apparent density, and 60 % higher energy consumption. The residue formation mechanism involves the initial deposition of a dense copper layer that bonds firmly to the Cu substrate, evolving into a residual layer after scraping. Ti initially showed low residue but degraded cyclically. Mo formed weakly adherent deposits that fragmented during scraping. In stark contrast, 316 L and Ta exhibited near-zero residue accumulation, consistently producing superior DCP with low apparent density (0.37–0.69 g cm −3 ) and fine particle size (10.02–29.82 μm). Surface characterization revealed that the presence of protective oxide layers on 316 L and Ta surfaces is key to inhibiting residue formation and corrosion. Ta emerged as the optimal cathode, achieving zero residue, exceptional corrosion resistance, stable high-quality DCP output, and minimal energy consumption during long-term operation.