Electrochemical Corrosion Engineering for Ni-Fe Oxides with Superior Activity toward Water Oxidation

The traditional synthesis for bimetallic-based electrocatalysts is challengeable for fine composition and elemental distribution because of the uncontrollable growth speed of nanostructures utilizing metal salt precursors. Herein, a unique electrochemical corrosion engineering strategy is developed via electrochemically transforming metal solid substrates (iron foil and nickel foam) into a highly active Ni-Fe oxide film for oxygen evolution, rather than directly utilizing metal ion precursors. This synthesis involves electrochemical corrosion of a Fe foil in an aqueous electrolyte along with electrochemical passivation of Ni foam (NF). The released trace Fe ions gradually incorporate into passivated NF surfaces to construct Ni-Fe oxide film and crucially improve composition distribution in the catalyst film. As a result, the resulted film with an ultralow mass loading (0.22 mg cm^-2) delivers large current densities of 500 mA cm^-2 at overpotential of only 270 mV in 6.0 M KOH at 60 °C, outperforming many reported NiFe catalysts requiring much higher mass loadings. More interestingly, the as-prepared catalyst almost reaches the standard (500 mA cm^-2 within the overpotential of 300 mV) in commercial water electrolysis with long-term stability for at least 10 h. This work may provide a unique synthesis strategy for nonprecious transition-metal catalysts for desirable water splitting and can be expanded to many other electrocatalysis systems.