Synthesis, Characterization, and Electrochemical Evaluation of Electrodeposited NiCuZn Powders for Urea Oxidation

The growing demand for sustainable energy technologies has intensified interest in direct urea fuel cells as an environmentally friendly energy conversion system. In this work, a ternary NiCuZn electrocatalyst is synthesized via a single-step electrodeposition process, offering a rapid and scalable alternative to commonly used hydrothermal or multistep fabrication routes. Structural and compositional analyses (SEM, EDX) confirm the formation of coral-shaped particles of NiCuZn powders. Electrochemical evaluation in alkaline media demonstrates that powders of both tested variants exhibit clear anodic activity, with peak potentials in the range of 0.4–0.6 Vvs Ag|AgCl (sat. KCl). Zinc presence was confirmed also after the process. Upon urea addition, a pronounced enhancement in anodic current density is observed. Notably, variant NiCuZn powder, which was produced using higher current density during electrodeposition, shows superior catalytic activity from approximately 0.4 Vvs Ag|AgCl (sat. KCl), reaching a maximum of 10 mA/cm2 near 0.75 Vvs Ag|AgCl (sat. KCl), and stability, which are attributed to its highly homogeneous microstructure and dynamic surface activation mechanism uniquely by partial zinc leaching during operation. These findings demonstrate that electrodeposited NiCuZn systems can deliver competitive performance despite their structural simplicity, highlighting their potential as cost-effective and scalable anode materials for direct urea fuel cell applications. We address a critical bottleneck in fuel cell manufacturing by replacing time-intensive hydrothermal syntheses with a rapid, highly scalable electrodeposition method. Furthermore, the identification of zinc-leaching mechanisms provides crucial new insights into dynamic catalyst activation, moving beyond traditional, static anode designs.