Exploring the Structure–Function Relationship in Iridium–Cobalt Oxide Catalyst for Oxygen Evolution Reaction across Different Electrolyte Media

Renewable hydrogen generation from water electrolysis offers a viable path to decarbonization if the costs can be reduced. The iridium-based anode catalyst is one of the most expensive components in electrolyzers. We propose reducing iridium usage by substituting Ir with Co, a more affordable metal, in the mixed oxide phase to enhance the catalytic activity while minimizing Ir consumption. A modified surfactant-assisted Adams fusion synthesis technique was developed as a scalable method for producing IrCo oxide nanoparticles. The synthesized material outperforms the commercial baseline, iridium oxide with carbon (IrOx_C), in both acidic and alkaline media. Acid etching (IrCo_ae) further enhances activity by selectively removing Co to expose more active sites. IrCo_ae achieved a significantly lower overpotential at 10 mA/cm2 compared to IrOx_C, with reductions of approximately 18% under acidic conditions and 14% under alkaline conditions. This work demonstrates that the proposed synthesis method enables efficient Ir utilization and can be adapted to enhance catalyst stability for renewable hydrogen production.