Chemical Bath Deposition of NiFe Alloy Anode for Efficient Alkaline Water Electrolyzer Integration

Green hydrogen production from water splitting is a feasible way for intermittent renewable energy storage and utilization, where the exploration and scale-up preparation of high-performance anodic oxygen evolution electrocatalysts are critical prerequisites for its industrial-level applications. Herein, a chemical bath deposition of FeNi₃ intermetallic alloys onto Ni mesh support is performed, which delivers a current density of 0.62 A cm^-2 at 1.72 V versus reversible hydrogen electrode for alkaline water oxidation in 1 m KOH and an excellent electrolysis stability at 0.2 A cm^-2 for over 300 h. Moreover, via 3D computational fluid dynamics simulation and flow field optimization, a homogeneous deposition of ≈5400 cm² NiFe anode is demonstrated within 4 min using the developed flow bath reactor. Once integrating the as-prepared NiFe anodes into alkaline electrolyzer stack, the voltage variation between each unit cell is below 40 mV at a total operation current of 71 A, or ca. current density of 0.2 A cm^-2, confirming the uniformity of this batch synthesis protocol and its great potential for industrial alkaline water electrolysis.