Fabrication of highly efficient FeNi-based electrodes using thermal plasma spray for electrocatalytic oxygen evolution reaction

Electrochemical water splitting has emerged as a promising approach for efficient energy production, drawing significant attention in recent research. However, the key challenge lies in identifying cost-effective and highly efficient electrocatalysts based on earth -abundant materials as alternatives to noble metals. Transition metals have garnered considerable interest due to their favorable properties: cost-effectiveness, superior performance, and long-term stability. In this study, we focused on the fabrication of FeNi-based electrocatalysts using atmospheric plasma spray in various mole ratio mixtures of FeNi (1:1, 1:2, 1:3). The phase and elemental composition of the prepared electrocatalysts were analyzed through X-ray diffraction, X-ray photoelectron spectroscopy, and energy -dispersive X-ray spectroscopy. Electrochemical characterization was performed using a three -electrode system. Among the different mole ratio compositions, FeNi (1:3) exhibited remarkable activity towards the Oxygen Evolution Reaction (OER), with an overpotential of 313 mV and a Tafel slope of 64.03 mV/dec at 20 mA cm -2. Furthermore, FeNi demonstrated excellent stability in OER activity even after 1000 cycles. The surface morphology of the coatings before and after electrochemical reactions was examined using Scanning electron microscopy. This study highlights the successful fabrication of FeNi-based electrocatalysts via atmospheric plasma spray, showcasing their potential as binder -free and highly stable electrocatalysts for electrochemical water -splitting applications.