Iranian Journal of Materials Science and Engineering

en Galvanostatic Deposition of Iron Powder from Sulfate Electrolytes: Experimental Analysis and Empirical Modeling گروه استخراج Metallurgical Extraction and Processing Research Paper Research Paper Producing high-purity iron powders with controlled particle morphology is essential for advanced powder metallurgy, additive manufacturing, and functional materials. However, achieving precise morphological control in environmentally benign, additive-free electrolytes remains challenging. This study systematically investigates the galvanostatic electrodeposition of iron powder from sulfate-based electrolytes containing 10.0 and 50.0 g·L⁻¹ Fe²⁺, focusing on the interplay between current density, pH evolution, deposition efficiency, and particle structure. A clear transition from compact, adherent deposits at low current densities to dendritic, easily detachable powders at higher values was observed. SEM analysis revealed well-defined dendritic aggregates at 7 A·dm⁻² (30–80 μm), whereas highly fragmented, porous agglomerates formed at 10 A·dm⁻², accompanied by fine-scale fragmentation driven by intense hydrogen evolution. XRD confirmed pure α-Fe for current densities up to 7 A·dm⁻², while partial oxidation to Fe₃O₄ occurred at 10 A·dm⁻²; EDX mapping further supported this surface oxidation. The deposited mass increased linearly with current density for both Fe²⁺ concentrations, with regression models yielding R² values above 0.96. Current efficiency decreased at high current densities due to enhanced parasitic reactions. Overall, the results demonstrate that galvanostatic electrodeposition in additive-free sulfate media enables controlled synthesis of iron powders, with tunable morphology and phase purity governed primarily by current density and electrolyte composition. iron powder,galvanostatic electrolysis,sulphate electrolyte,current efficiency,SEM morphology 0 0 http://ijmse.iust.ac.ir/browse.php?a_code=A-10-6015-1&slc_lang=en&sid=1 Daniela Grigorova d.dimitrova@uctm.edu 1800319475328460022186 1800319475328460022186 Yes University of Chemical Technology and MetallurgyDepartment of Metallurgical Technologies, Electrotechnics and Electronics Gyunver Hodjaoglu gyunver@ipc.bas.bg 1800319475328460022187 1800319475328460022187 No 1Institute of Physical Chemistry “Acad. R. Kaischew”, Bulgarian Academy of Sciences Feyzim Hodzhaoglu feyzim@ipc.bas.bg 1800319475328460022188 1800319475328460022188 No Institute of Physical Chemistry “Acad. R. Kaischew”, Bulgarian Academy of Sciences, Acad.