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<p>Stainless-steel coatings were fabricated using the arc-wire spraying technique and assessed for the first time as electrocatalysts for the hydrogen evolution reaction (HER) in alkaline media. Coatings were deposited on sandblasted mild-steel substrates using optimized parameters (30.9&#xa0;V, 135.9 A, 3.1&#xa0;m&#xa0;min⁻<sup>1</sup> wire feed, 4.8&#xa0;bar air pressure, 140&#xa0;mm spray distance). EPMA–WDS and XRD analyses revealed a dense lamellar structure composed of Fe–Cr–Ni metallic phases with minor Fe<sub>2</sub>O<sub>3</sub> and Cr<sub>2</sub>O<sub>3</sub> inclusions. Nanoindentation showed high mechanical performance (H ≈ 3.76 GPa; E ≈ 100 GPa) and strong interfacial adhesion. Electrochemical testing in 1.0&#xa0;M KOH demonstrated a low η₁₀₀ potential of 0.19&#xa0;V vs. RHE, a Tafel slope of 0.76&#xa0;V dec⁻<sup>1</sup>, and a hydrogen evolution rate of 1181&#xa0;µmol&#xa0;h⁻<sup>1</sup>, confirming efficient catalytic activity and stability. These findings establish arc-wire–sprayed stainless-steel coatings as robust, scalable, and cost-effective electrodes for HER.</p>

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Arc-wire–sprayed stainless-steel coatings as robust and cost-effective electrocatalysts for the hydrogen evolution reaction (HER)

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Khaled Derkaoui,
  • Yamina Mebdoua,
  • Douaa Baizid,
  • Chaker Serdani,
  • Hadj Lahmar,
  • Naitbouda Abdelyamine,
  • Soumia Benredouane,
  • Boukhouidem Khadidja,
  • Billel Hamdoud,
  • Toufik Hadjersi

摘要

Stainless-steel coatings were fabricated using the arc-wire spraying technique and assessed for the first time as electrocatalysts for the hydrogen evolution reaction (HER) in alkaline media. Coatings were deposited on sandblasted mild-steel substrates using optimized parameters (30.9 V, 135.9 A, 3.1 m min⁻1 wire feed, 4.8 bar air pressure, 140 mm spray distance). EPMA–WDS and XRD analyses revealed a dense lamellar structure composed of Fe–Cr–Ni metallic phases with minor Fe2O3 and Cr2O3 inclusions. Nanoindentation showed high mechanical performance (H ≈ 3.76 GPa; E ≈ 100 GPa) and strong interfacial adhesion. Electrochemical testing in 1.0 M KOH demonstrated a low η₁₀₀ potential of 0.19 V vs. RHE, a Tafel slope of 0.76 V dec⁻1, and a hydrogen evolution rate of 1181 µmol h⁻1, confirming efficient catalytic activity and stability. These findings establish arc-wire–sprayed stainless-steel coatings as robust, scalable, and cost-effective electrodes for HER.