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<p>Cold spray technology is applied for the first time to fabricate nickel electrodes for the hydrogen evolution reaction (HER). This solid-state deposition process accelerates Ni particles to supersonic velocities, consolidating them into dense, adherent, and binder-free coatings while preserving chemical purity and crystallinity. The resulting electrode presents a rough, textured morphology with an enlarged electrochemically active surface area, a highly crystalline fcc structure with preferential (111) orientation, and a favorable Ni/NiO heterointerface that enhances electron transfer and water dissociation. Electrochemical testing in alkaline medium demonstrates excellent performance, with a low onset potential of –0.32 V vs. RHE, high current density (–120 mA cm<sup>−2</sup> at –1.0 V), a Tafel slope of ~ 122 mV dec<sup>−1</sup>, and an exchange current density of 1.64 mA cm<sup>−2</sup>. Electrochemical impedance spectroscopy indicates moderate charge-transfer resistance with efficient ionic diffusion, while hydrogen quantification confirms a stable production rate of 472 µmol h<sup>−1</sup>. These results demonstrate that cold spraying offers a scalable and environmentally friendly route for producing high-performance Ni electrodes for alkaline water electrolysis.</p>

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Binder-free cold-sprayed Ni electrodes: a scalable route toward high performance hydrogen evolution catalyst

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Khaled Derkaoui,
  • Yamina Mebdoua,
  • Amira Djaibet,
  • Hadil Laiche,
  • Chaker Serdani,
  • Hadj Lahmar,
  • Soumia Benredouane,
  • Khadidja Boukhouidem,
  • Naitbouda Abdelyamine,
  • Samia Lemboub,
  • Toufik Hadjersi

摘要

Cold spray technology is applied for the first time to fabricate nickel electrodes for the hydrogen evolution reaction (HER). This solid-state deposition process accelerates Ni particles to supersonic velocities, consolidating them into dense, adherent, and binder-free coatings while preserving chemical purity and crystallinity. The resulting electrode presents a rough, textured morphology with an enlarged electrochemically active surface area, a highly crystalline fcc structure with preferential (111) orientation, and a favorable Ni/NiO heterointerface that enhances electron transfer and water dissociation. Electrochemical testing in alkaline medium demonstrates excellent performance, with a low onset potential of –0.32 V vs. RHE, high current density (–120 mA cm−2 at –1.0 V), a Tafel slope of ~ 122 mV dec−1, and an exchange current density of 1.64 mA cm−2. Electrochemical impedance spectroscopy indicates moderate charge-transfer resistance with efficient ionic diffusion, while hydrogen quantification confirms a stable production rate of 472 µmol h−1. These results demonstrate that cold spraying offers a scalable and environmentally friendly route for producing high-performance Ni electrodes for alkaline water electrolysis.