Dislocation Network-Boosted PtNi Nanocatalysts Welded on Nickel Foam for Efficient and Durable Hydrogen Evolution at Ultrahigh Current Densities

Large-scale application of alkaline water electrolysis for high-rate hydrogen production is severely hindered by high electricity cost, mainly due to difficulties to acquire cost-effective catalytic electrodes with both extremely low overpotential and long-term durability at ultrahigh current densities (≥1 A cm⁻²). Here it is demonstrated that by adopting a synthetic method of laser direct writing in liquid nitrogen via a commercial laser welding machine, a remarkably efficient and durable electrode with large area and low platinum content is obtained, where PtNi nanocatalysts with dislocation network are firmly welded on a nickel foam (NF). The dense dislocation network not only improves intrinsic activity of a majority of surface-active sites induced by coupled compressive-tensile strains synergistically promoting both Volmer and Tafel steps of alkaline hydrogen evolution reaction (HER), but also well stabilizes surface dislocations for HER at ultrahigh current densities. Such a robust electrode achieves record-low overpotentials of 5 and 63 mV at 10 and 1000 mA cm⁻² in alkaline medium, respectively, exhibiting negligible activity decay after 300 h chronoamperometric test at 1 A cm⁻². It displays a high Pt mass activity 16 times higher than 20 wt% Pt/C loaded on NF, surpassing most of the recently reported efficient Pt-based catalysts.