A scalable Al-Ni alloy powder catalyst prepared by metallurgical microstructure control

Scalable and facile synthesis of highly active alkaline hydrogen evolution reaction catalysts was demonstrated by controlling the microstructures of Al-Ni alloys and making porous foam and powder. The microstructures were carefully controlled in the binary alloys and the subsequent selective etching resulted in highly active catalysts, which are comparable to conventional Pt-based catalysts. Large-scale coating of a dealloyed Al-Ni alloy powder was also demonstrated, showing the practical applicability of this method. Metallurgical microstructure control of Al-Ni alloys enabled scalable and facile synthesis of large-area electrodes for alkaline hydrogen evolution catalysts comparable to conventional Pt catalysts.