Comparative evaluation of Ni and Cu/Ni coated electrodes experimentally for alkaline electrolysis

In the field, key research focuses on developing cost-effective, efficient and environmentally friendly solutions for alkaline water electrolysis, as the need for hydrogen is expected to further rise exponentially in the upcoming years, and alkaline water electrolysis serves as a clean hydrogen production method when the process is driven by renewable energy sources. In this study, fused deposition modelling (FDM) technology is utilized in the manufacturing of the electrodes with varying geometries effectively, which are subjected to electrodeposition of Ni and Cu/Ni coating on the electrode surface. The hydrogen evolution reaction (HER) performance of the 3D printed electrodes in alkaline media is evaluated through electrochemical performance measurements. It is determined that the electrochemical activity of the 3D printed electrodes varied according to the surface geometry, aspect ratio, and coating material utilized. The Cu/Ni coated rectangular geometry electrode with an aspect ratio of 0.1 exhibited an overpotential of 238 mV at a current density of −10 mA/cm 2 , and the Ni coated rectangular geometry electrode with an aspect ratio of 0.2 achieved an overpotential of 269 mV at the equivalent current density. The 3D printed electrodes with varying surface geometries, aspect ratios, and catalysts, developed in this study, present a potential solution toward enhancing the HER performance of 3D printed electrodes in alkaline media. • The 3D printed electrodes are prepared sustainably toward electrolysis. • Ni and Ni–Cu coated electrodes with varying geometries are utilized. • The electrodes are evaluated by electrochemical and structural characterizations. • The study investigates various parameters that influence electrode performance.