No idea about the foam. My first idea is contaminants/surfactants.
It's CO2 caused by the reaction of localised hydronium ions (caused by the reaction of ferric ions with water) at the anode with the bicarb.
Aside from the anodic processes you mention, with a steel electrode, and depending on both your cell geometry and reaction velocity, the applied potential can cause the iron to oxidise to ferric ion (as I discuss on another thread).
I'm only a newcomer to this forum myself, but the plethora of people (and threads) now talking about this same subject is becoming a little tedious.
Mostly they are newcomers, and mostly they know almost no chemistry. They call electrolytes catalysts, ask questions about ridiculous electrolytes such as bicarb, and don't understand answers when they are given.
Anyone who is involved with any automotive forums will know that these threads are now legion. Everyone, it seems, is interested in saving money by bolting an electrolysis cell onto their engine. Anyone who understands the science behind this idea that questions the testimonies that accompany these claims, is shot down in flames, with arguments that usually boil down to
1. We haven't heard about this because big oil has stopped it (usually with an accompanying story about an inventor who was mysteriously murdered by Big Oil)
2. The laws of thermodynamics are made to be broken (I kid you not)
3. You don't know if you don't try. Those of us with a formal science education are "stuck in our thinking" and don't know how to try new ideas.
4. Anything that's on the internet must be true. Anyone who doesn't believe in the existence of molecules such as HHO and monatomic hydrogen (at STP) has been brainwashed by their formal education.
And so, what is happening is that now some people who have believed that they can knock up in their garage a device that will produce results that the combined efforts of the world's best automotive engineers cannot, have actually tried some of these devices.
And, now that they have discovered that they don't work, they think "oh - I know - I'll ask some scientists - they'll be able to answer all my questions."
So, to anyone in this category, let me give you a hand. It won't work. I have a PhD in electrochemistry, and I can tell you that the design of electrolysis cells is a hideously complex science, with concepts such as overvoltage, junction potentials, ionic mobilites and diffusion coefficients, Butler-Volmer equilibria, interfacial electron transfer kinetics, electrode resistivity and potential gradients, etc., etc.
But you don't need to understand any of this to know that it won't work. I'd have thought that the complete absence of this technology on any car currently being built or proposed would make it obvious to anyone whose IQ was greater than that of an apricot that it won't work.
To come onto this forum and to expect to be able to ask how to build one of these devices with a few tips is like a kindergarten child asking for tips on how to build a space shuttle.