Corrosion of nickel foam electrodes during hydrothermal reactions: The influence of a simple protective carbon black coating

Nickel foam (NF) substrates are widely used to support electrocatalysts, and this is frequently achieved using hydrothermal reactions, where the NF is immersed in the hydrothermal reactor together with the electrocatalyst precursors. However, other reactions including the corrosion of the NF and changes to the pH occur simultaneously, and these can affect the quality of the final electrocatalyst. Herein, a simple approach is devised to minimise these unwanted reactions. Carbon black (CB) was non-covalently functionalised at room temperature using tannic acid to give very stable and good dispersions of fCB in deionised water. Using a simple sonication step, the NF was coated with a uniform layer of the dispersed fCB. This layer served to minimise the corrosion of the underlying NF during the hydrothermal reactions with very good protection observed up to a temperature of 160 °C in deionised water at a pH of 2.0. The corrosion currents of the NF and fCB@NF were estimated at 8.7 µA and 3.9 µA, respectively, at room temperature in this acidic solution. Using a model reaction, the successful nucleation and growth of MnCo₂O₄ cubes was observed at fCB@NF, but not at the corroding NF.