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<p>As a clean energy, hydrogen has great potential to promote energy transformation and sustainable production. Water electrolysis is a promising pathway for green hydrogen production. Currently, industrial-scale hydrogen production primarily employs transition metal-based catalysts, but their catalytic efficiencies are significantly lower than the theoretical limits, which restrict the energy efficiency and large-scale application of water electrolysis for hydrogen production. In this study, NiCoW catalytic coatings with different W contents were deposited on nickel mesh substrates by atmospheric plasma spraying, and then the specimens were activated via the dealloying technique. Micromorphologies and phase compositions of the catalytic coatings before and after activation were characterized, and catalytic properties of the specimens were systematically analyzed. The results show that the specimen with a Co:W mass ratio of 13:7 demonstrates optimal hydrogen evolution reaction performance. The hydrogen evolution reaction overpotential is 41.8&#xa0;mV at a current density of 10&#xa0;mA·cm<sup>−2</sup>, and the Tafel slope is 65&#xa0;mV·dec<sup>−1</sup>. Furthermore, during the overall water electrolysis process, the voltage required for the current density of 10&#xa0;mA·cm<sup>−2</sup> is 1.57&#xa0;V.</p>

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Catalytic Properties of Atmospheric Plasma-Sprayed Coatings for Alkaline Water Electrolysis Hydrogen Production Systems

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Zhenglong Sun,
  • Xi Tan,
  • Jianhong Gao,
  • Qinggui Li,
  • Shuoyu Wang,
  • Zhengkang Wu,
  • Guijun Ding,
  • Xiaohong Hu,
  • Zhiyong Zhong

摘要

As a clean energy, hydrogen has great potential to promote energy transformation and sustainable production. Water electrolysis is a promising pathway for green hydrogen production. Currently, industrial-scale hydrogen production primarily employs transition metal-based catalysts, but their catalytic efficiencies are significantly lower than the theoretical limits, which restrict the energy efficiency and large-scale application of water electrolysis for hydrogen production. In this study, NiCoW catalytic coatings with different W contents were deposited on nickel mesh substrates by atmospheric plasma spraying, and then the specimens were activated via the dealloying technique. Micromorphologies and phase compositions of the catalytic coatings before and after activation were characterized, and catalytic properties of the specimens were systematically analyzed. The results show that the specimen with a Co:W mass ratio of 13:7 demonstrates optimal hydrogen evolution reaction performance. The hydrogen evolution reaction overpotential is 41.8 mV at a current density of 10 mA·cm−2, and the Tafel slope is 65 mV·dec−1. Furthermore, during the overall water electrolysis process, the voltage required for the current density of 10 mA·cm−2 is 1.57 V.