Porous carbon foams are an exciting area of research because they are lightweight, electrically conductive, and have extremely high surface areas. Coating these foams with TiO₂ makes them chemically active, enabling their use in energy storage devices, fuel cells, hydrogen production, CO₂‑reduction catalysts, photocatalysis, and thermal management systems. While many studies have examined the outer surfaces of coated foams, much less is known about how TiO₂ coatings behave deep inside the foam structure.

In this study, researchers deposited TiO₂ thin films onto carbon foams using magnetron sputtering and applied different bias voltages to control ion energy, which in turn affects coating density, crystal structure, thickness, and adhesion. They analysed both the outer surface and the interior of the foam using microscopy, particle‑transport simulations, and X‑ray techniques.

They found that the TiO₂ coating on the outer surface is dense, correctly composed, and crystalline (mainly anatase with a small amount of rutile) ideal for catalytic and energy applications. They also discovered that although fewer particles reach deep inside the foam, those do retain the same energy, meaning particle quantity decreases with depth but particle energy does not. Because devices like batteries and supercapacitors rely on uniform coatings, variations in thickness or structure inside the foam can lead to poorer performance and faster degradation.

Overall, this research provides a much clearer understanding of how TiO₂ coatings grow inside complex 3D foams, showing how thickness, density, and crystal structure evolve with depth and how bias voltage can be used to tune these properties. By revealing how plasma particles move through the foam and validating models that predict coating behaviour, it enables the design of more reliable, higher‑performing foam‑based devices for energy and catalytic applications.

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Advances in thermal conductivity for energy applications: a review Qiye Zheng et al. (2021)