Amazing work Ken!
Your protocol seems ok, the only variable is the plating process. Frank and Harper used chloride salts (either for Pd or Fe), I used Fe + HCl, J.P. Biberian used also chlorides and bromides. I suspect that a lower pH is needed in order to either increase the H+ concentration and codeposition, and also to modify the plating structure at micro/nano level (increasing the number of defects).
All pictures I saw from successful replications had a coating that looked quite "ugly". In my first successful replication I was very disappointed with the plating result!
I recap my protocol, in case you would to try it out:
- start with a clean and finely sanded brass electrode as cathode
- use as electrolyte tap water with about 5% of HCl (I used 1/4 in volume of 20% HCl)
- use a number of 1 mm iron wires evenly spaced around the cathode, at a short distance (< 1 cm)
- start with a current density of about 100 uA/cm^2 for one hour then about 200 uA/cm^2 for another hour (resulting voltage should be around 200 mV)
- increase the current at about 2 mA/cm^2 for about 3 or 4 hour (voltage will be around 300 mV)
- you have to gradually increase the voltage in order to keep the desired current, within the above mentined limits
- In this first part of the process you should note a sensible evolution of hydrogen at the cathode and almost no plating forming
- After about 4 or 5 hours, you should note that the gas evolution stops or reduces a lot, the current will also decrease: this is the start of the second part of the process
- Increase the voltage so that the current will be about 3-5 mA/cm^2. The resulting voltage will be about 500 mV (do not exceed 600 mV). Keep this setting for about 4 hour
- You should note that from that moment the cathode starts to plate with a black coating, the hydrogen evolution is small and the current will maintain quite stable
- After these last 4 hours, take out the cathode, that will look kind of carbon black, not shining at all. Rinse and dry very well with a towel. Do not use an oven and do not take too much time, because it will rust very rapidly! However take all the measures so to avoid unwanted wet contacts.
Assemble a LEC with a brass, copper or aluminium counter-electrode, and measure the voltage: after a few minutes it will rise to some 100s mV (hopefully! ).