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Abstract

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 (FE_C2H4 = 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.