Optimizing NiFe-Modified Graphite for Enhanced Catalytic Performance in Alkaline Water Electrolysis: Influence of Substrate Geometry and Catalyst Loading

The oxygen evolution reaction (OER) and the hydrogen evolution reaction (HER) are critical processes in water splitting, yet achieving efficient performance with minimal overpotential remains a significant challenge. Although NiFe-based catalysts are widely studied, their performance can be further enhanced by optimizing the interaction between the catalyst and the substrate. Here, we present a detailed investigation of NiFe-modified graphite electrodes, comparing the effects of compressed and expanded graphite substrates on catalytic performance. Our study reveals that substrate geometry plays a pivotal role in catalyst distribution and activity, with expanded graphite facilitating more effective electron transfer and active site utilization. Additionally, we observe that increasing the NiFe loading leads to only modest gains in performance, due to catalyst agglomeration at higher loadings. The optimized NiFe-graphite composites exhibit superior stability and catalytic activity, achieving lower overpotentials and higher current densities, making them promising candidates for sustainable hydrogen production via alkaline electrolysis.