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DC Magnetron Sputtering for Synthesizing Bimetallic NiFe Thin Films as Efficient OER-Catalyzing Electrodes
Daniyal Hasan1, Albano Cavaleiro1,2, Diogo Cavaleiro1
1Centre for Mechanical Engineering, Materials and Processes (CEMMPRE), Department of Mechanical Engineering, University of Coimbra, 3030-788 Coimbra, Portugal.
Materials (Basel, Switzerland)
|August 13, 2026
Summary
This study explores using scalable DC magnetron sputtering to create earth-abundant nickel-iron (NiFe) thin films for hydrogen production via water electrolysis. Optimized NiFe films show promising performance as low-cost oxygen evolution reaction (OER) electrocatalysts.
Area of Science:
- Materials Science
- Electrochemistry
- Catalysis
Background:
- Noble metal catalysts like RuO2/IrO2 are standard for oxygen evolution reaction (OER) in industrial water electrolysis.
- Developing earth-abundant alternatives is crucial for cost-effective hydrogen production.
- Scalable synthesis with controlled structure is needed for NiFe-based catalysts.
Purpose of the Study:
- Investigate DC magnetron sputtering as a scalable method for synthesizing NiFe bimetallic thin-film electrocatalysts.
- Evaluate the influence of Fe content on the structural, morphological, and electrochemical properties of NiFe thin films.
- Identify optimal NiFe compositions for efficient OER catalysis as alternatives to noble metals.
Main Methods:
- DC magnetron sputtering to deposit NiFe thin films (~200 nm) with varying Fe content on SS-316L substrates.
- Characterization using scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS).
- Electrochemical testing to assess oxygen evolution reaction (OER) performance, including overpotential and current density.
Main Results:
- Sputtered NiFe thin films exhibited a columnar morphology and formed a random solid solution.
- Fe content significantly impacted OER performance; Fe24Ni76 showed the highest activity.
- The Fe24Ni76 catalyst required an overpotential of 361 mV to reach 10 mA·cm-2 and achieved 363 mA·cm-2 at 1.7 V.
- Enhanced activity was attributed to increased Ni oxidation and a higher density of active oxide species.
Conclusions:
- DC magnetron sputtering is a viable scalable technique for producing NiFe thin-film electrocatalysts.
- Optimized NiFe compositions, like Fe24Ni76, demonstrate excellent OER activity.
- These NiFe thin films are promising low-cost, high-performance alternatives for next-generation water electrolysis systems.
