Revealing the Fe doping effect on Ni catalysts for low alkalinity OER: from three-electrode systems to continuous flow anion exchange membrane water electrolyser

Here, we report the use of magnetic induction heating as a rapid and efficient synthesis method to produce Fe@Ni nanoparticles (NPs) with tunable surface coverage and their application as catalysts in the oxygen evolution reaction (OER). This approach enables localized thermal decomposition of precursors, offering improved control over catalyst phase formation. To bridge the gap between lab-scale materials and practical electrolyser integration, the catalysts were deposited onto commercially available Ni-mesh supports suitable for Anion Exchange Membrane Water Electrolyser (AEMWE) operation. The influence of iron content on OER activity was evaluated, and the catalyst performance was validated in a full-cell electrolyser, highlighting the potential of this synthesis route for scalable green hydrogen technologies. • Magnetically induced heating allows control over catalysts surface composition. • Fe affects the performance of nickel catalysts for oxygen evolution reaction. • Addressing the synergistic effect of electrode supporting materials on catalytic activity. • Transition from three-electrode system until full-cell electrolyser.