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<p>Plasma-sprayed CoNiCrAlY alloy and yttria-stabilized zirconia (ZrO<sub>2</sub> + 8% Y<sub>2</sub>O<sub>3</sub>) coatings were investigated as scalable electrodes for the hydrogen evolution reaction (HER) in alkaline media. Coatings were deposited on mild steel substrates using atmospheric plasma spraying, followed by detailed structural, morphological, and electrochemical characterization. The CoNiCrAlY alloy exhibited a dense face-centered cubic (FCC) structure, while the ceramic displayed a stabilized tetragonal phase. Surface profilometry revealed high roughness values for both coatings (Ra = 14.742&#xa0;µm for CoNiCrAlY, 12.55&#xa0;µm for YSZ), enhancing surface area. Electrochemical measurements revealed that CoNiCrAlY exhibited enhanced HER activity, evidenced by a lower Tafel slope (0.1627 V/dec), higher exchange current density (4311.86 mA/cm<sup>2</sup>), and faster hydrogen evolution rate (5092.98 μmol/h) compared to YSZ (0.3186 V/dec, 711.22 mA/cm<sup>2</sup>, 3547.55 μmol/h). Electrochemical impedance spectroscopy confirmed lower charge transfer resistance and Warburg-type diffusion behavior for the metallic coating. Raman spectroscopy identified protective oxide layers (Cr<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub>) on the alloy surface, which contribute to increased durability. These findings highlight the promising catalytic performance and scalability of CoNiCrAlY coatings for alkaline water electrolysis.</p>

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Exploring plasma-sprayed MCrAlY and yttria-stabilized zirconia coatings for efficient and scalable hydrogen production

  • 期刊论文

  • 发表日期：

    2025年7月24日

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  • Khaled Derkaoui,
  • Yamina Mebdoua,
  • Lalla Garagouze,
  • Nour El Houda Ahmed Merdoukh,
  • Chaker Serdani,
  • Hadj Lahmar,
  • Soumia Benredouane,
  • Nadjet Bouhelal,
  • Naitbouda Abdelyamine,
  • Maissa Bourahla,
  • Toufik Hadjersi

摘要

Plasma-sprayed CoNiCrAlY alloy and yttria-stabilized zirconia (ZrO2 + 8% Y2O3) coatings were investigated as scalable electrodes for the hydrogen evolution reaction (HER) in alkaline media. Coatings were deposited on mild steel substrates using atmospheric plasma spraying, followed by detailed structural, morphological, and electrochemical characterization. The CoNiCrAlY alloy exhibited a dense face-centered cubic (FCC) structure, while the ceramic displayed a stabilized tetragonal phase. Surface profilometry revealed high roughness values for both coatings (Ra = 14.742 µm for CoNiCrAlY, 12.55 µm for YSZ), enhancing surface area. Electrochemical measurements revealed that CoNiCrAlY exhibited enhanced HER activity, evidenced by a lower Tafel slope (0.1627 V/dec), higher exchange current density (4311.86 mA/cm2), and faster hydrogen evolution rate (5092.98 μmol/h) compared to YSZ (0.3186 V/dec, 711.22 mA/cm2, 3547.55 μmol/h). Electrochemical impedance spectroscopy confirmed lower charge transfer resistance and Warburg-type diffusion behavior for the metallic coating. Raman spectroscopy identified protective oxide layers (Cr2O3, Al2O3) on the alloy surface, which contribute to increased durability. These findings highlight the promising catalytic performance and scalability of CoNiCrAlY coatings for alkaline water electrolysis.