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<p>Alkaline water electrolysis (AWE) for highly efficient hydrogen production requires a highly active cathode. In this work, the porous NiAlMo electrodes were prepared by plasma spraying of NiAlMo and Al powders with a dual-channel powder feeding strategy. The bilayer-structured electrode consisting of a NiAlMo bond coat and a NiAlMo-Al composite coating on the top was designed. Al particles in the composite coating were used as pore former. The effect of Al powder feeding off-set distance on the molten state of Al was examined for optimizing the pore structure. The activated NiAlMo-40Al/NiAlMo electrode exhibited an apparent porosity of 36.8% and a surface roughness of Ra 12.18&#xa0;μm, with an overpotential of 34.22&#xa0;mV at 10&#xa0;mA&#xa0;cm<sup>−2</sup> and a Tafel slope of 27.71&#xa0;mV dec<sup>−1</sup>, which was much lower than that of traditional NiAlMo electrodes. After a CP test for 10&#xa0;h, the electrode remained intact and showed a stable overpotential of -0.34&#xa0;V.</p>

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High performance NiAlMo cathode with dual-mode porous structure by plasma spraying for alkaline water electrolysis hydrogen production

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月3日

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  • Yue-Ting Wang,
  • Xiao-Chen Bu,
  • Xiao-Tao Luo,
  • Zi-Pei Zhao,
  • Zhi-Gang Li,
  • Jian-Hui Liu,
  • Chen-Tian Zheng,
  • Chang-Jiu Li

摘要

Alkaline water electrolysis (AWE) for highly efficient hydrogen production requires a highly active cathode. In this work, the porous NiAlMo electrodes were prepared by plasma spraying of NiAlMo and Al powders with a dual-channel powder feeding strategy. The bilayer-structured electrode consisting of a NiAlMo bond coat and a NiAlMo-Al composite coating on the top was designed. Al particles in the composite coating were used as pore former. The effect of Al powder feeding off-set distance on the molten state of Al was examined for optimizing the pore structure. The activated NiAlMo-40Al/NiAlMo electrode exhibited an apparent porosity of 36.8% and a surface roughness of Ra 12.18 μm, with an overpotential of 34.22 mV at 10 mA cm−2 and a Tafel slope of 27.71 mV dec−1, which was much lower than that of traditional NiAlMo electrodes. After a CP test for 10 h, the electrode remained intact and showed a stable overpotential of -0.34 V.