From powder morphology to catalytic behavior: Unraveling the role of spherical/flaky Al powders in cold-sprayed coating’s electrochemical activity for alkaline electrolysis

IF 6.3 2区材料科学 Q2 CHEMISTRY, PHYSICAL

Surfaces and Interfaces Pub Date : 2025-10-04 DOI:10.1016/j.surfin.2025.107799

Xiangyun Zhang , Guang Xu , Liangliang He , Taikai Liu , Yingchun Xie , Peiqing La

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Abstract

Hydrogen energy is regarded as a promising clean alternative to fossil fuels, yet the efficiency of hydrogen evolution reaction (HER) in alkaline electrolytes remains limited by the low catalytic activity of nickel-based electrodes. In this study, porous Ni electrodes were fabricated via cold spraying mixed powders of Ni + spherical Al or Ni + flake Al onto Ni substrates, followed by activation treatment. The influence of powder morphology on the porous structure and catalytic performance was systematically investigated. The Ni + spherical Al electrode exhibited remarkable HER activity, requiring only 0.32 V and 0.42 V overpotentials to achieve current densities of -100 and -250 mA cm⁻², respectively, while maintaining excellent durability under long-term cycling. These remarkable HER performance can be attributed to the synergistic effects of large electrochemical active surface area, excellent HER stability, and superior charge transfer capability.

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从粉末形态到催化行为：揭示球形/片状Al粉末在冷喷涂涂层碱性电解电化学活性中的作用

氢能被认为是一种很有前途的替代化石燃料的清洁能源，但在碱性电解质中析氢反应（HER）的效率仍然受到镍基电极催化活性低的限制。在本研究中，通过在Ni衬底上冷喷涂Ni +球形Al或Ni +片状Al混合粉末，然后进行活化处理，制备多孔Ni电极。系统地研究了粉末形貌对多孔结构和催化性能的影响。Ni +球形Al电极表现出显著的HER活性，只需要0.32 V和0.42 V过电位就可以分别达到-100和-250 mA cm -²的电流密度，同时在长期循环下保持优异的耐久性。这些优异的HER性能可归因于大的电化学活性表面积、优异的HER稳定性和优越的电荷转移能力的协同作用。

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来源期刊

Surfaces and Interfaces Chemistry-General Chemistry

CiteScore

8.50

自引率

6.50%

发文量

753

审稿时长

35 days

期刊介绍： The aim of the journal is to provide a respectful outlet for ''sound science'' papers in all research areas on surfaces and interfaces. We define sound science papers as papers that describe new and well-executed research, but that do not necessarily provide brand new insights or are merely a description of research results. Surfaces and Interfaces publishes research papers in all fields of surface science which may not always find the right home on first submission to our Elsevier sister journals (Applied Surface, Surface and Coatings Technology, Thin Solid Films)