There have been tremendous advances in the materials, knowledge, desig
n, and construction of cathodes; however, widely divergent cell operat
ions and operating conditions present a challenge for selecting the ri
ght materials and lining design for good cell life. Cathode wear is fr
equently becoming the life-determining step, and, although there are q
uestions still to be answered, it is probable that particulate detachm
ent (physical wear) plays an important role in parallel with carbide d
issolution. If wear cannot be controlled by smart design and operation
s, coating technology may offer benefits for extending the life of cat
hode linings by reducing or eliminating wear. Thus, it would also enab
le softer graphitic materials to be utilized more readily, and this ad
vantage will become more important if the trend toward higher current
density continues.