Enhanced oxygen evolution reaction of electrodeposited Functionally-Graded Ni-Cu-Fe coating

•The functionally-graded Ni-Cu-Fe coating was successfully produced.•The increase of the current density and “Fe” changed the number of active areas.•The presence of “Fe” in the Ni-Cu coating improved the OER activity.•The minimum overpotential was related to the Ni-Cu-Fe (FG) coating. This study aimed to use a functionally graded (FG) Ni-Cu-Fe coating as an electrocatalyst for oxygen evolution reaction (OER) applications. The coating was applied on a mild carbon steel substrate by an electrodeposition technique, with the current density being progressively increased from 0.5 A/dm2 to 5 A/dm2 at a steady rate of 0.2 (A/dm2)/min during the coating operation. Using this specific method, the Ni content of the FG Ni-Cu-Fe coating changed along the cross-section when increasing the current density, 17 % more than the constant current coating. This technique also affected the surface morphology of the FG Ni-Cu-‌Fe coating and changed it from cauliflower to micro/nanocones when the current density was linearly increased, enhancing active sites significantly and thereby improving electrocatalytic activity. The coating's electrocatalytic behavior was studied by electrochemical impedance spectroscopy (EIS), linear sweep voltammetry (LSV), and cyclic voltammetry (CV). results showed that the FG Ni-Cu-Fe coating had the smallest overpotential (134 mV) at the current density of 10 mA.cm−2. Also, it had the smallest Tafel slope (24.3 mV.dec− 1) and smallest resistance (598 Ω.cm2) compared to all of the other coatings. The FG Ni-Cu-‌‌Fe coating had higher OER performance because of high Ni content, micro/nanocones morphology with many active sites, and FG nature. The FG Ni-Cu-Fe coating is finally concluded to be a promising and economical catalyst with high OER activity.