Recent Advances in Metal Oxide-Coated Anodes for Industrial Electrochemical Applications: Emphasis on RuO2-and IrO2-Based Systems, Failure Mechanisms, and Coating Technologies

Anode materials play a pivotal role in a wide range of electrochemical applications, including electrolysis, energy storage, corrosion protection, and industrial oxidation processes. This review provides a comprehensive analysis of recent advances in anode materials, with particular emphasis on their structural characteristics and major preparation methods, including thermal decomposition, electrochemical deposition, sol–gel processing, and magnetron sputtering. The degradation behaviour of anodes under electrochemical operating conditions is also critically discussed, together with strategies for improving their durability and overall performance. Particular attention is given to metal oxide-coated anodes, especially those based on ruthenium oxide (RuO2) and iridium oxide (IrO2), which remain the most representative systems in dimensionally stable anode (DSA) research and industrial applications. Emerging coating materials, including Co3O4- and carbon-based catalysts, are also reviewed as promising alternatives for reducing noble metal usage while maintaining acceptable electrochemical performance. In addition, the role of intermediate layers in titanium-based anodes is examined, with emphasis on their contribution to coating adhesion, conductivity, interfacial stability, and long-term electrode performance. This review further discusses the applications of anode materials in chlorine- and oxygen-related electrochemical industries and evaluates the performance of DSAs in relation to substrate selection, coating composition, and operational requirements. Alternative furnace technologies for anode baking are also reviewed, including conventional furnace heating, laser heating, and microwave heating, together with representative industrial furnace systems such as muffle, continuous, and vacuum furnaces. Overall, this review provides an integrated overview of the current progress in anode material research and development, while highlighting the key challenges and future directions for improving anode efficiency, durability, and sustainability in industrial electrochemical applications.