Post-mortem analysis of AWE electrodes

Post-mortem analysis is the most valuable tool to improve the next design. At Jolt Solutions we analyse every electrode retired from a customer plant: 100% traceability, 0% assumptions.

Most frequent failure modes

• Coating loss by delamination (38%) — Common cause: repeated thermal shock.
• Catalytic contamination (24%) — Iron, calcium or silica from the electrolyte.
• Catalyst sintering (18%) — Extended operation above 85 °C.
• Mechanical bubble erosion (12%) — Sub-optimal flow-field design.
• Substrate corrosion (8%) — Usually from pH excursions.

Every finding feeds the product roadmap. The next generation, SPARKFUZE™ AWE-C300, incorporates improvements directly derived from these analyses.