Correlation of Morphology and Crystal Structure of Metal Powders Produced by Electrolysis Processes

In this review paper, morphologies of metal powders produced by the constant (potentiostatic and galvanostatic) regimes of electrolysis from aqueous electrolytes are correlated with their crystal structure at the semiquantitative level. The main parameters affecting the shape of powder particles are the exchange current density (rate of electrochemical process) and overpotential for hydrogen evolution reaction. Depending on them, various shapes of dendrites (the needles, the two-dimensional (2D) fern-like, and the three-dimensional (3D) pine-like dendrites), and the particles formed under vigorous hydrogen evolution (cauliflower-like and spongy-like particles) are produced by these regimes of electrolysis. By decreasing the exchange current density value, the crystal structure of the powder particles is changed from the strong (111) preferred orientation obtained for the needle-like (silver) and the 2D (lead) dendrites to the randomly orientated crystallites in particles with the spherical morphology (the 3D dendrites and the cauliflower-like and the spongy-like particles). The formation of metal powders by molten salt electrolysis and by electrolysis in deep eutectic solvents (DESs) and the crystallographic aspects of dendritic growth are also mentioned in this review.