Engineered Three-Dimensional Electrodes by HVOF Process for Hydrogen Production

High velocity oxy-fuel process was used to prepare nickel electrode coatings for hydrogen production by alkaline water electrolysis. To further increase the active surface area of the electrodes, pyramidal fin arrays with two different sizes were deposited on the top surface of the electrodes using mesh screen masks. The surface microstructure, topology and roughness of the coatings were studied using scanning electron microscope, optical microscopy and confocal laser scanning microscopy. Steady-state polarization curves were used to evaluate the electrocatalytic activity of the electrodes. The performance of the electrodes coated using mesh outperformed the electrode deposited without using mesh. In addition, the electrode that was coated using the coarse mesh was characterized with the highest activity with the exchange current density and overpotential values of 9.3 × 10^?3 A/cm² and ?306 mV, respectively. Formation of different roughness levels due to the combination of normal and off-normal impact of the coating particles on the surface of the fins was identified as the main factor for the increased activity of this electrode toward the hydrogen evolution reaction.