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This work demonstrated the large potential of sputtered iridium metal for catalytic reactions shown by the example of decomposition of hydrogen peroxide (H 2 O 2 ) for space propulsion systems. For this purpose, iridium was coated onto Al 2 O 3  pellets by a sputter process under varied process parameters. Depending on previously selected parameters, the obtained metal-loaded pellets offer closed- and/or open-shell structures. Catalytic productivity of these first-generation iridium-sputtered catalysts was estimated in laboratory experiments and compared to platinum-loaded pellets. Under optimized sputter-process conditions, the reactivity is significantly improved compared to the platinum-impregnated pellets. The better catalytic productivity can be explained by the increased active surface area of the iridium layers on the pellets. The surface morphology and the microstructure of the iridium coating can be actively controlled by the sputter pressure. The results are in accordance with the sputtering process pressure tendency described by the Thornton Structure–Zone Model. Graphical abstract

Sputtered highly effective iridium catalysts: a new approach for green satellite propulsion