Enhanced electrochemical synthesis of Ni–Fe/brass foil alloy with subsequent combustion for high-performance photoelectrode and hydrogen production applications

Abstract This study presents a novel approach to synthesizing and characterizing Cu–Fe–Ni ternary alloy and oxide nanostructures for advanced electrochemical and photocatalytic applications. Using electrodeposition on brass substrates from tailored solutions of Nickel( ii )chloride, nickel( ii ) sulfate, and iron( iii ) chloride, five distinct alloy compositions were fabricated with optimized morphologies and electrochemical properties. Notably, succinic acid was identified as an effective additive, enhancing deposition quality and catalytic activity. A unique ternary alloy oxide was further synthesized via controlled combustion at 950°C. Comprehensive characterization using X-ray diffraction, X-ray photoelectron spectroscopy, scanning electron microscope, Energy dispersive X-ray, and cyclic voltammetry revealed significant structure–property relationships. Alloys formed with higher Ni and Fe chloride concentrations showed rough, agglomerated surfaces, correlating with improved hydrogen evolution reaction performance in alkaline sodium hydroxide. Among all samples, Alloy( v ) exhibited the highest hydrogen production efficiency. Furthermore, the alloy oxide demonstrated remarkable photovoltaic potential, delivering current densities of 23 mA·cm −2 in the dark and 68.45 mA·cm −2 under illumination. These findings showcase a cost-effective, scalable method for producing multifunctional Cu–Fe–Ni-based materials with dual capabilities in hydrogen generation and solar energy conversion – highlighting a new direction in renewable energy material development.