The Stability Challenges of Oxygen Evolving Catalysts: Towards a Common Fundamental Understanding and Mitigation of Catalyst Degradation

Metal-oxygen bonding characteristics dictate activity and stability differences of RuO2 and IrO2 in the acidic oxygen evolution reaction

Ruthenium dioxide (RuO2) and iridium dioxide (IrO2) serve as benchmark electrocatalysts for the acidic oxygen evolution reaction (OER), yet their intrinsic activity-stability relationships remain elusive. Herein, we employ density functional theory (DFT) calculations to systematically investigate the origin of divergent OER catalytic behaviors between RuO2 and IrO2 in acidic media. Mechanistic analyses reveal that RuO2 follows the adsorbate evolution mechanism with superior activity (theoretical overpotential: 0.698 V vs. 0.909 V for IrO2), while IrO2 demonstrates enhanced stability due to a higher dissolution energy change (>2.9 eV vs. -0.306 eV for RuO2). Electronic structure analysis reveals that RuO2 exhibits ionic-dominated metal-oxygen bonds with delocalized electron distribution, facilitating intermediate desorption but promoting detrimental RuO42- dissolution. In contrast, IrO2 features covalent bonding characteristics with more electron filling in Ir-oxygen bonds (2.942 vs. 2.412 for RuO2), thereby stabilizing surface intermediates against dissolution at the expense of higher OER barriers. This work establishes a clear correlation between the bonding nature and electrocatalytic performance metrics, offering fundamental insights for the rational design of acid-stable OER electrocatalysts with optimized activity-stability relationships.

Engineering the regulation strategy of active sites to explore the intrinsic mechanism over single‑atom catalysts in electrocatalysis

The development of efficient and sustainable energy sources is a crucial strategy for addressing energy and environmental crises, with a particular focus on high-performance catalysts. Single-atom catalysts (SACs) have attracted significant attention because of their exceptionally high atom utilization efficiency and outstanding selectivity, offering broad application prospects in energy development and chemical production. This review systematically summarizes the latest research progress on SACs in five key electrochemical reactions: hydrogen evolution reaction, oxygen reduction reaction, carbon dioxide reduction reaction, nitrogen reduction reaction, and oxygen evolution reaction. Initially, a brief overview of the current understanding of electrocatalytic active sites in SACs is provided. Subsequently, the electrocatalytic mechanisms of these reactions are discussed. Emphasis is placed on various modification strategies for SAC surface-active sites, including coordination environment regulation, electronic structure modulation, support structure regulation, the introduction of structural defects, and multifunctional site design, all aimed at enhancing electrocatalytic performance. This review comprehensively examines SAC deactivation and poisoning mechanisms, highlighting the importance of stability enhancement for practical applications. It also explores the integration of density functional theory calculations and machine learning to elucidate the fundamental principles of catalyst design and performance optimization. Furthermore, various synthesis strategies for industrial-scale production are summarized, providing insights into commercialization. Finally, perspectives on future research directions for SACs are highlighted, including synthesis strategies, deeper insights into active sites, the application of artificial intelligence tools, and standardized testing and performance requirements.

Sub-4 nm Ru-RuO2 Schottky Nanojunction as a Catalyst for Durable Acidic Water Oxidation

RuO2 with high intrinsic activity for water oxidation is a promising alternative to IrO2 in proton exchange membrane (PEM) electrolyzer, but it suffers from long-term stability issues due to overoxidation. Here, we report a sub-4 nm Ru-RuO2 Schottky nanojunction (Ru-RuO2-SN) prepared by a microwave reaction that exhibits high activity and long-term stability in both three-electrode systems and PEM devices. The lattice strain and charge transfer induced by the metal-oxide SN increase the work function of the Ru-RuO2-SN, optimize the local electronic structure, and reduce the desorption energy of the metal site to the oxygen-containing intermediates; as a result, it leads to the oxide path mechanism (OPM) and inhibits the excessive oxidation of surface ruthenium. The Ru-RuO2-SN requires only 165 mV overpotential to obtain 10 mA·cm-2 with 1400 h stability without obvious activity degradation, achieving a stability number (6.7 × 106) matching iridium-based catalysts. In a PEM electrolyzer with Ru-RuO2-SN as an anode catalyst, only 1.6 V is needed to reach 1.0 A·cm-2 and it shows long-term stability at 100 mA·cm-2 for 1100 h and at 500 mA·cm-2 for 100 h. The reaction mechanism for the high stability of Ru-RuO2-SN was analyzed by density functional theory calculations. This work reports a durable, pure Ru-based water-oxidation catalyst and provides a new perspective for the development of efficient Ru-based catalysts.

Anode Alchemy on Multiscale: Engineering from Intrinsic Activity to Impedance Optimization for Efficient Water Electrolysis

The past decade has seen significant progress in proton exchange membrane water electrolyzers (PEMWE), but the growing demand for cost-effective electrolytic hydrogen pushes for higher efficiency at lower costs. As a complex system, the performance of PEMWE is governed by a combination of multiscale factors. This review summarizes the latest progress from quantum to macroscopic scales. At the quantum level, electron spin configurations can be optimized to enhance catalytic activity. At the nano and meso scales, advancements in atomic structure optimization, crystal phase engineering, and heterostructure design improve catalytic performance and mass transport. At the macro scale, innovative techniques in gas bubble management and internal resistance reduction drive further efficiency gains under ampere-level operating conditions. These modifications at the quantum level cascade through meso- and macro-scales, affecting charge transfer, reaction kinetics, and gas evolution management. Unlike conventional approaches that focus solely on one scale-either at the catalyst level (e.g., atomic, or crystal modifications) or at the device level (e.g., porous transport layers design)-combining multiscale optimizations unlocks greater performance improvements. Finally, a perspective on future opportunities for multiscale engineering in PEMWE anode design toward commercial viability is offered.

Operando evidence on the chirality-enhanced oxygen evolution reaction in intrinsically chiral electrocatalysts

Electrolytic hydrogen is identified as a crucial component in the desired decarbonisation of the chemical industry, utilizing renewable energy to split water into hydrogen and oxygen. Water electrolysis still requires important scientific advances to improve its performance and lower its costs. One of the bottlenecks in this direction is related to the sluggish anodic oxygen evolution reaction (OER). Producing anodes with competitive performance remains challenging due to the high energy losses and the harsh working conditions typically required by this complex oxidation process. Recent advancements point to spin polarization as an opportunity to enhance the kinetics of this spin-restricted reaction, yielding the paramagnetic O2 molecule. One powerful strategy deals with the generation of chiral catalytic surfaces, typically by surface functionalisation with chiral organic molecules, to promote the chiral-induced spin selectivity (CISS) effect during electron transfer. However, the relationship between optical activity and enhanced electrocatalysis has been established only from indirect experimental evidence. In this work, we have exploited operando electrochemical and spectroscopic tools to confirm the direct relationship between the faster OER kinetics and the optical activity of enantiopure Fe-Ni metal oxides when compared with that of achiral catalysts in alkaline conditions. Our results show the participation of chiral species as reactive intermediates during the electrocatalytic reaction, supporting the appearance of a mechanistic CISS enhancement. Furthermore, these intrinsically chiral transition-metal oxides maintain their enhanced activity in full cell electrolyser architectures at industrially relevant current densities.

Iridium Nanocrystals Enriched with Defects and Atomic Steps to Enhance Oxygen Evolution Reaction Performance

The presence of defects can significantly improve catalytic activity and stability, as they influence the binding of the reactants, intermediates, and products to the catalyst. Controlling defects in the structures of nanocrystal catalysts is synthetically challenging. In this study, we demonstrate the ability to control the growth of Ir nanocrystals, enabling the tuning of both structural and surface defects. The Ir nanocrystals have unique structures that range from single crystals of a few nanometers to twinned nanoparticles and multiply twinned crystallites with a high density of atomic steps. This approach of defect engineering enables us to understand their roles in enhancing the performance of the OER and producing an Ir catalyst with both high activity and stability. Our results show the importance of the concept of using synthetic control of structural and surface defects in metal nanoparticles as a strategy to improve catalytic performance.

Silicon Carbide Photonic Crystal Photoelectrode

The immense challenge of large-scale implementation of photoelectrochemical (PEC) water splitting and carbon fixation lies in the need for a cheap, durable, and efficacious photocatalyst. Cubic silicon carbide (3C-SiC) holds compelling potential due to its auspicious band positions and high-volume, high-quality, single crystal industrial manufacturing, but is hindered by its inferior light absorptivity and anodic instability. A slanted parabolic pore photonic crystal (spbPore PC) architecture with graphitic carbon nitride (g-CN), nickel(II) oxide (NiO), or 6H silicon carbide protective coatings is proposed to overcome the drawbacks of 3C-SiC photoelectrodes. A 30 µm- and 62 µm-thick 3C-SiC spbPore PC of lattice constant 0.8 µm demonstrates maximum achievable photocurrent density (MAPD) of 9.95 and 11.53 mA cm-2 in the [280.5, 600] nm region, respectively, representing 75.7% and 87.7% of the total available solar photocurrent density in this spectral range. A 50 nm-thick g-CN or NiO coating forms type-II heterojunctions with the 3C-SiC spbPore PC, facilitating the charge transport and enhancing the corrosion resistivity, all together demonstrating the MAPD of 9.81 and 10.06 mA cm-2, respectively, for 30 µm-thick PC. The scheme advances the low-cost, sustainable, real-world deployment of PEC cells for green solar fuel production.

Active phase discovery in heterogeneous catalysis via topology-guided sampling and machine learning

Understanding active phases across interfaces, interphases, and even within the bulk under varying external conditions and environmental species is critical for advancing heterogeneous catalysis. Describing these phases through computational models faces the challenges in the generation and calculation of a vast array of atomic configurations. Here, we present a framework for the automatic and efficient exploration of active phases. This approach utilizes a topology-based algorithm leveraging persistent homology to systematically sample configurations across diverse coordination environments and material morphologies. Simultaneously, efficient machine learning force fields enable rapid computations. We demonstrate the effectiveness of this framework in two systems: hydrogen absorption in Pd, where hydrogen penetrates subsurface layers and the bulk, inducing a "hex" reconstruction critical for CO2 electroreduction, explored through 50,000 sampled configurations; and the oxidation dynamics of Pt clusters, where oxygen incorporation renders the clusters less active during oxygen reduction reactions, investigated through 100,000 sampled configurations. In both cases, the predicted active phases and their impacts on catalytic mechanisms closely align with previous experimental observations, indicating that the proposed strategy can model complex catalytic systems and discovery active phases under specific environmental conditions.

Hydroxylation Strategy Enables Ru-Mn Oxide for Stable Proton Exchange Membrane Water Electrolysis under 1 A cm-2

Ruthenium (Ru)-based catalysts have demonstrated promising utilization potentiality to replace the much expensive iridium (Ir)-based ones for proton exchange membrane water electrolysis (PEMWE) due to their high electrochemical activity and low cost. However, the susceptibility of RuO2-based materials to easily be oxidized to high-valent and soluble Ru species during the oxygen evolution reaction (OER) in acid media hinders the practical application, especially under current density above 500 mA cm-2. Here, a manganese-doped RuO2 catalyst with the hydroxylated metal sites (i.e., H-Mn0.1Ru0.9O2) is synthesized for acidic OER assisted by hydrogen peroxide, where the hydroxylation results in the valence state of the Ru sites below +4. The H-Mn0.1Ru0.9O2 catalyst demonstrates an overpotential of 169 mV at 10 mA cm-2 and promising stability for an OER over 1000 h in an acidic electrolyte. A PEMWE device fabricated with the H-Mn0.1Ru0.9O2 catalyst as the anode shows a current density of 1 A cm-2 at ∼1.65 V, along with a low degradation over continuous tens of hours. Differential electrochemical mass spectrometry (DEMS) results and theoretical calculations confirm that H-Mn0.1Ru0.9O2 performs the OER through the adsorbate evolution mechanism (AEM) pathway, where the synergistic effect of hydroxylation and Mn doping in RuO2 can effectively enhance the stability of Ru sites and lattice oxygen atoms.

Durable Acidic Oxygen Evolution Via Self-Construction of Iridium Oxide/Iridium-Tantalum Oxide Bi-Layer Nanostructure with Dynamic Replenishment of Active Sites

Proton exchange membrane (PEM) water electrolysis presents considerable advantages in green hydrogen production. Nevertheless, oxygen evolution reaction (OER) catalysts in PEM water electrolysis currently encounter several pressing challenges, including high noble metal loading, low mass activity, and inadequate durability, which impede their practical application and commercialization. Here we report a self-constructed layered catalyst for acidic OER by directly using an Ir-Ta-based metallic glass as the matrix, featuring a nanoporous IrO2 surface formed in situ on the amorphous IrTaOx nanostructure during OER. This distinctive architecture significantly enhances the accessibility and utilization of Ir, achieving a high mass activity of 1.06 A mgIr-1 at a 300 mV overpotential, 13.6 and 31.2 times greater than commercial Ir/C and IrO2, respectively. The catalyst also exhibits superb stability under industrial-relevant current densities in acid, indicating its potential for practical uses. Our analyses reveal that the coordinated nature of the surface-active Ir species is effectively modulated through electronic interaction between Ir and Ta, preventing them from rapidly evolving into high valence states and suppressing the lattice oxygen participation. Furthermore, the underlying IrTaOx dynamically replenishes the depletion of surface-active sites through inward crystallization and selective dissolution, thereby ensuring the catalyst's long-term durability.

Cobalt-Doped Ru@RuO2 Core-Shell Heterostructure for Efficient Acidic Water Oxidation in Low-Ru-Loading Proton Exchange Membrane Water Electrolyzers

Proton exchange membrane water electrolysis (PEMWE) is a highly promising hydrogen production technology for enabling a sustainable energy supply. Herein, we synthesize a single-atom Co-doped core-shell heterostructured Ru@RuO2 (Co-Ru@RuO2) catalyst via a combination of ultrafast pulse-heating and calcination methods as an iridium (Ir)-free and durable oxygen evolution reaction (OER) catalyst in acidic conditions. Co-Ru@RuO2 exhibits a low overpotential of 203 mV and excellent stability over a 400 h durability test at 10 mA cm-2. When implemented in industrial PEMWE devices, a current density of 1 A cm-2 is achieved with only 1.58 V under an extremely low catalyst loading of 0.34 mgRu cm-2, which is decreased by 4 to 6 times as compared to other reported Ru-based catalysts. Even at 500 mA cm-2, the PEMWE device could work stably for more than 200 h. Structural characterizations and density functional theory (DFT) calculations reveal that the single-atom Co doping and the core-shell heterostructure of Ru@RuO2 modulate the electronic structure of pristine RuO2, which reduce the energy barriers of OER and improve the stability of surface Ru. This work provides a unique avenue to guide future developments on low-cost PEMWE devices for hydrogen production.

Impacts of Surface Reconstruction and Metal Dissolution on Ru1-x Ti x O2 Acidic Oxygen Evolution Electrocatalysts

Improved oxygen evolution reaction (OER) electrocatalysts based on an additional understanding of surface changes that occur upon metal dissolution are needed to enable the efficient use of electrochemical water splitting. This work integrates theoretical and experimental studies of the effects of metal dissolution from the RuO2 and Ru1-x Ti x O2 surfaces on the OER activity and electrochemical stability. Our computational analysis shows that the energetic barriers for metal dissolution depend highly on the surface site and Ti-substituent location. Metal dissolution induces the formation of new active surface sites with different electronic density distributions. In addition to dissolution-induced changes to the surface composition, electron density changes occur in the interfacial electrolyte components. Surface reconstruction changes the activation barriers for the OER steps. Our experimental analysis of RuO2 and Ru0.8Ti0.2O2 using a two-step durability test in acidic electrolytes shows that the OER activity, surface, and metal dissolution change over the durability tests. Ti-substitution exhibits improved electrochemical stability with cycling. For RuO2, changes in the mass activity of RuO2 with cycling are directly correlated with Ru dissolution and lowering of the electrochemical surface area (ECSA). In contrast, Ru0.8Ti0.2O2 showed a 19 times lower Ru dissolution rate, and metal dissolution results in increasing the ECSA and new active sites. Our STEM and EELS analysis supports that repeated cycling under OER conditions results in surface reconstruction for both RuO2 and Ru0.8Ti0.2O2, with the formation of a disordered RuO2 surface and changes to the distribution of Ru and Ti at the Ru0.8Ti0.2O2 surface. The experimentally observed changes in activity and surface structure after cycling are consistent with computational analysis, which shows how metal dissolution may alter the OER activation barriers. Combining experimental and computational insights, this work reveals the effects of metal dissolution on the surface atomic and electronic structure and OER activity and advances our comprehension of metal dissolution dynamics and surface reconstruction, which may have implications for other catalytic processes.

Dual Doping in Precious Metal Oxides: Accelerating Acidic Oxygen Evolution Reaction

Developing a highly active and stable catalyst for acidic oxygen evolution reactions (OERs), the key half-reaction for proton exchange membrane water electrolysis, has been one of the most cutting-edge topics in electrocatalysis. A dual-doping strategy optimizes the catalyst electronic environment, modifies the coordination environment, generates vacancies, and introduces strain effects through the synergistic effect of two elements to achieve high catalytic performance. In this review, we summarize the progress of dual doping in RuO2 or IrO2 for acidic OERs. The three main mechanisms of OERs are dicussed firstly, followed by a detailed examination of the development history of dual-doping catalysts, from experimentally driven dual-doping systems to machine learning (ML) and theoretical screening of dual-doping systems. Lastly, we provide a summary of the remaining challenges and future prospects, offering valuable insights into dual doping for acidic OERs.

Switchable Acidic Oxygen Evolution Mechanisms on Atomic Skin of Ruthenium Metallene Oxides

RuO2 has been considered as a promising, low-cost, and highly efficient catalyst in the acidic oxygen evolution reaction (OER). However, it suffers from poor stability due to the inevitable involvement of the lattice oxygen mechanism (LOM). Here, we construct a unique metallene-based core-skin structure and unveil that the OER pathway of atomic RuO2 skin can be regulated from the LOM to an adsorbate evolution mechanism by altering the core species from metallene oxides to metallenes. This switch is achieved without sacrificing the number of active sites, enabling Pd@RuO2 metallenes to exhibit outstanding acidic OER activity with a low overpotential of 189 mV at 10 mA cm-2, which is 54 mV lower than that of the counterpart PdO@RuO2 metallenes. Additionally, they also exhibit robust stability with negligible activity decay over 100 h at 50 mA cm-2, outperforming most reported RuO2-based catalysts. Multiple spectroscopic analyses and theoretical calculations demonstrate that the Pd-metallene core, acting as an electron donor, increases the migration energy of subsurface oxygen atoms and optimizes the adsorption energy of intermediates on the active Ru sites, enabling a switch in the reaction mechanism. Such a unique metallene-based core-skin structure offers a novel way for tuning the catalytic behaviors of electrocatalysts.

Highly dispersed Ir nanoparticles on Ti3C2Tx MXene nanosheets for efficient oxygen evolution in acidic media

The industrialization of hydrogen production technology through polymer electrolyte membrane water splitting faces challenges due to high iridium (Ir) loading on the anode catalyst layer. While rational design of oxygen evolution reaction (OER) electrocatalysts aimed at effective iridium utilization is promising, it remains a challenging task. Herein, we present exfoliated Ti3C2Tx MXene as a highly conductive and corrosion-resistant support for acidic OER. We develop an alcohol reduction method to achieve uniform and dense loading of ultrafine Ir nanoparticles on the MXene surface. The IrO2/TiOx heterointerface is formed in situ on the Ir@Ti3C2Tx MXene surface, acting as a catalytically active phase for OER during electrocatalysis. The electron interactions at the IrO2/TiOx heterointerface create electron-rich Ir sites, which reduce the adsorption properties of oxygen intermediates and enhance intrinsic OER activity. Consequently, the prepared Ir@Ti3C2Tx exhibits a mass activity that is 7 times greater than that of the benchmark IrO2 catalyst for OER in acidic media. In addition, the /Ti3C2Tx MXene support can stabilize the Ir nanoparticles, so that the stability number of Ir@Ti3C2Tx MXene is about 2.4 times higher than that of the IrO2 catalyst.

Laser induced oxidation Raman spectroscopy as an analysis tool for iridium-based oxygen evolution catalysts

The study of degradation behavior of electrocatalysts in an industrial context calls for rapid and efficient analysis methods. Optical methods like Raman spectroscopy fulfil these requirements and are thus predestined for this purpose. However, the iridium utilized in proton exchange membrane electrolysis (PEMEL) is Raman inactive in its metallic state. This work demonstrates the high oxidation sensitivity of iridium and its utilization in analysis of catalyst materials. Laser induced oxidation Raman spectroscopy (LIORS) is established as a novel method for qualitative, chemical and structural analysis of iridium catalysts. Differences in particle sizes of iridium powders drastically change oxidation sensitivity. Oxidation of the iridium powders to IrO2 occurred at a laser power density of 0.47 ± 0.06 mW μm-2 for the 850 μm powder and at 0.12 ± 0.06 mW μm-2 and 0.019 ± 0.015 mW μm-2 for the 50 μm and 0.7-0.9 μm powders respectively. LIORS was utilized to assess possible deterioration of an iridium electrocatalyst due to operation under electrolysis. The operating electrocatalyst exhibited higher oxidation sensitivity, suggesting smaller iridium particle size due to catalyst dissolution. Peak shifts of the IrO2 signal were utilized to assess differences in transformation temperatures. The operated electrocatalyst transformed to IrO2 at lower temperature (8 cm-1 redshift) relative to the pristine catalyst (10 cm-1 redshift), demonstrating that pre-oxidation of the iridium to amorphous IrOx during electrolysis diminishes the energy barrier needed for IrO2 formation. Thus, LIORS can be utilized as a straightforward screening method for the analysis of iridium electrocatalysts in the industrial application of PEMEL.

Size-Controllable High-Entropy Alloys Toward Stable Hydrogen Production at Industrial-Scale Current Densities

Efficient and stable electrocatalytic hydrogen evolution reaction (HER) at high current densities is highly desirable for industrial-scale hydrogen production, which is yet challenging, because of the electrocatalyst with short lifespans during the acidic HER process. Here, a controllable preparation technique is successfully developed to synthesize PdPtRuRhAu high-entropy alloys (HEAs) of various sizes, within the 3.14 nm particles (HEA-3.14) demonstrating exceptional catalytic performance and stable hydrogen production at current densities of -500 and -1000 mA·cm-2 with negligible activity loss over 100 h. Theoretical calculations indicate that the bridge adsorption site of Pd-Au serves as an ideal location for HER, with HEA-3.14 possessing the highest proportion of such sites, reaching 18.97%. To further analyze the thermodynamic stability of HEAs, an element-encoding machine learning model is developed from over 300 000 preprocessed dataset of HEAs that achieving an impressively low RMSE of 58.6 °C and a high R2 value of 0.98. By integrating thermodynamic modeling with machine learning methods, the melting point of the PdPtRuRhAu HEAs at 3.14 nm (366 °C) is predicted, which aligns well with the results obtained from differential scanning calorimetry tests. This work offers new insights and approaches for designing HEAs that reliably produce hydrogen at high current densities.

Oxygen Reduction Reaction Coupled Electro-Oxidation for Highly-Efficient and Sustainable Water Treatment

Electro-oxidation (EO) technology demonstrates significant potential in wastewater treatment. However, the high energy consumption has become a pivotal constraint hindering its large-scale implementation. Herein, we design an EO and 4-electron oxygen reduction reaction coupled system (EO-4eORR) to replace the traditional EO and hydrogen evolution reaction (HER) coupled system (EO-HER). The theoretical cathodic potential of the electrolytic reactor is tuned from 0 V (vs. RHE) in HER to 1.23 V (vs. RHE) in 4eORR, which greatly decreases the required operation voltage of the reactor. Moreover, we demonstrate that convection can improve the mass transfer of oxygen and organic pollutants in the reaction system, leading to low cathodic polarization and high pollutant removal rate. Compared with traditional EO-HER system, the energy consumption of the EO-4eORR system under air aeration for 95 % total organic carbon (TOC) removal is greatly decreased to 2.61 kWh/kgTOC (only consider the electrolyzer energy consumption), which is superior to previously reported EO-based water treatment systems. The reported results in this study offer a new technical mode for development of highly efficient and sustainable EO-based treatment systems to remove organic pollutants in waste water.

Metal oxide plating for maximizing the performance of ruthenium(IV) oxide-catalyzed electrochemical oxygen evolution reaction

Hydrogen production by proton exchange membrane water electrolysis requires an anode with low overpotential for oxygen evolution reaction (OER) and robustness in acidic solution. While exploring new electrode materials to improve the performance and durability, optimizing the morphology of typical materials using new methods is a big challenge in materials science. RuO2 is one of the most active and stable electrocatalysts, but further improvement in its performance and cost reduction must be achieved for practical use. Herein, we present a novel technology, named "metal oxide plating", which can provide maximum performances with minimum amount. A uniform single-crystal RuO2 film with thickness of ∼2.5 nm was synthesized by a solvothermal-post heating method at an amount (x) of only 18 μg cm-2 (ST-RuO2(18)//TiO2 NWA). OER stably proceeds on ST-RuO2(18)//TiO2 NWA with ∼100% efficiency to provide a mass-specific activity (MSA) of 341 A gcat-1 at 1.50 V (vs. RHE), exceeding the values for most of the state-of-the-art RuO2 electrodes.

Ensuring Stability of Anode Catalysts in PEMWE: From Material Design to Practical Application

Proton Exchange Membrane Water Electrolysis (PEMWE) has emerged as a clean and effective approach for the conversion and storage of renewable electricity, particularly due to its compatibility with fluctuating photovoltaic and wind power. However, the high cost and limited performance of iridium oxide catalysts (i. e. IrO2) used as anode catalyst in industrial PEM electrolyzers remain significant obstacles to widespread application. Although numerous low-cost and efficient alternative catalysts have been developed in laboratory research, comprehensive stability studies critical for industrial use are often overlooked. This leads to the failure of performance transfer from catalysts tested in liquid half-cell systems to those employed in PEM electrolyzers. This concept presents a thorough overview for the stability issues of anode catalysts in PEMWE, and discuss their degradation mechanisms in both liquid half-cell systems and PEM electrolyzers. We summarize the comprehensive protocols for assessment and characterization, analyze the effective strategies for stability optimization, and explore the opportunities for designing viable anode catalysts for PEM electrolyzers.

Boosting the durability of RuO2 via confinement effect for proton exchange membrane water electrolyzer

Ruthenium dioxide has attracted extensive attention as a promising catalyst for oxygen evolution reaction in acid. However, the over-oxidation of RuO2 into soluble H2RuO5 species results in a poor durability, which hinders the practical application of RuO2 in proton exchange membrane water electrolysis. Here, we report a confinement strategy by enriching a high local concentration of in-situ formed H2RuO5 species, which can effectively suppress the RuO2 degradation by shifting the redox equilibrium away from the RuO2 over-oxidation, greatly boosting its durability during acidic oxygen evolution. Therefore, the confined RuO2 catalyst can continuously operate at 10 mA cm-2 for over 400 h with negligible attenuation, and has a 14.8 times higher stability number than the unconfined RuO2 catalyst. An electrolyzer cell using the confined RuO2 catalyst as anode displays a notable durability of 300 h at 500 mA cm-2 and at 60 °C. This work demonstrates a promising design strategy for durable oxygen evolution reaction catalysts in acid via confinement engineering.

A one-pot hydrothermal synthesis of morphologically controllable yolk-shell structured CoFe glycerate spheres for oxygen evolution reaction

CoFe-based catalysts are efficient electrocatalysts for the oxygen evolution reaction (OER) in alkaline media. Here, we present a simple one-pot hydrothermal method for synthesizing a series of CoFe glycerates with controllable surface morphologies and investigate their potential as highly efficient catalysts for the OER in alkaline media. These CoFe glycerates exhibit a unique yolk-shell microsphere structure assembled from ultrathin nanosheets. The adjustment of the surface nanosheet size is achieved by varying the CoFe ratio, ensuring a more efficient electrocatalytic system for the OER process. Due to the abundant active sites provided by the yolk-shell structure and interleaved ultrathin nanosheets, Co3Fe1 glycerate (Co3Fe1 gly) demonstrates a low overpotential (283 mV) and a small Tafel slope (44.61 mV dec-1) at 10 mA cm-2. Additionally, Co3Fe1 gly exhibits excellent durability in alkaline electrolytes. Moreover, a series of characterizations demonstrate that the active sites of Co3Fe1 gly are the high-valence Co species generated during the OER process. This study opens a promising avenue for utilizing efficient and low-cost electrocatalysts to enhance OER performance.

Multitasking-Effect Ca Ions Triggered Symmetry-Breaking of RuO2 Coordination for Acidic Oxygen Evolution Reaction

The development of highly active and stable electrocatalysts for the acid oxygen evolution reaction (OER) is both appealing and challenging. The generation of defects is an emerging strategy for improving the water oxidation efficiency. Herein, we introduced multitasking Ca ions to trigger oxygen vacancies in RuO2, resulting in vacancy-rich RuO2 (RuO2-Ov) nanoparticles with enhanced and sustainable OER activity. The oxygen vacancy in RuO2-Ov breaks the symmetry of the RuO6 octahedron, enhancing the d-band center of Ru and reducing the level of 4d-2p hybridization in Ru-O bonds. This effectively optimizes intermediate adsorption and inhibits Ru dissolution. The RuO2-OV catalyst achieves a current density of 10 mA/cm2 with an overpotential of only 198 mV, stabilizing for over 100 h (degradation rate: 0.2 mV/h). Its mass activity is 17.9 times higher than that of commercial RuO2. Our work highlights that multitasking atomic construction defect engineering effectively balances the seesaw relationship between catalytic activity and stability.

Disentangling the Pitfalls of Rotating Disk Electrode-Based OER Stability Assessment: Bubble Blockage or Substrate Passivation?

Oxygen evolution reaction (OER) catalyst stability metrics derived from aqueous model systems (AMSs) prove valuable only if they are transferable to technical membrane electrode assembly (MEA) settings. Currently, there is consensus that stability data derived from ubiquitous rotating disk electrode (RDE)-based investigations substantially overestimate material degradation mainly due to the nonideal inertness of catalyst-backing electrode materials as well as bubble shielding of the catalyst by evolved oxygen. Despite the independently developed understanding of these two processes, their interplay and relative impact on intrinsic and operational material stability have not yet been established. Herein, we employ an inverted RDE-based approach coupled with online gas chromatographic quantification that exploits buoyancy and anode hydrophilicity existing under operating acidic OER conditions and excludes the influence of bubble retention on the surface of the catalyst. This approach thus allows us to dissect the degradation process occurring during the RDE-based OER stability studies. We demonstrate that the stability discrepancy between galvanostatic nanoparticle (NP)-based RDE and MEA data does not originate from the accumulation of bubbles in the catalyst layer during water oxidation but from the utilization of corrosion-prone substrate materials in the AMS. Moreover, we provide mechanistic insights into the degradation process and devise experimental measures to mitigate or circumvent RDE-related limitations when the technique is to be applied to an OER catalyst stability assessment. These findings should facilitate the transferability between AMS and MEA approaches and promote further development of the latter.

Atomically engineered interfaces inducing bridging oxygen-mediated deprotonation for enhanced oxygen evolution in acidic conditions

The development of efficient and stable electrocatalysts for water oxidation in acidic media is vital for the commercialization of the proton exchange membrane electrolyzers. In this work, we successfully construct Ru-O-Ir atomic interfaces for acidic oxygen evolution reaction (OER). The catalysts achieve overpotentials as low as 167, 300, and 390 mV at 10, 500, and 1500 mA cm-2 in 0.5 M H2SO4, respectively, with the electrocatalyst showing robust stability for >1000 h of operation at 10 mA cm-2 and negligible degradation after 200,000 cyclic voltammetry cycles. Operando spectroelectrochemical measurements together with theoretical investigations reveal that the OER pathway over the Ru-O-Ir active site is near-optimal, where the bridging oxygen site of Ir-OBRI serves as the proton acceptor to accelerate proton transfer on an adjacent Ru centre, breaking the typical adsorption-dissociation linear scaling relationship on a single Ru site and thus enhancing OER activity. Here, we show that rational design of multiple active sites can break the activity/stability trade-off commonly encountered for OER catalysts, offering good approaches towards high-performance acidic OER catalysts.

Reactivity and Stability of Reduced Ir-Weight TiO2-Supported Oxygen Evolution Catalysts for Proton Exchange Membrane (PEM) Water Electrolyzer Anodes

Reducing the iridium demand in Proton Exchange Membrane Water Electrolyzers (PEM WE) is a critical priority for the green hydrogen industry. This study reports the discovery of a TiO2-supported Ir@IrO(OH)x core-shell nanoparticle catalyst with reduced Ir content, which exhibits superior catalytic performance for the electrochemical oxygen evolution reaction (OER) compared to a commercial reference. The TiO2-supported Ir@IrO(OH)x core-shell nanoparticle configuration significantly enhances the OER Ir mass activity from 8 to approximately 150 A gIr-1 at 1.53 VRHE while reducing the iridium packing density from 1.6 to below 0.77 gIr cm-3. These advancements allow for viable anode layer thicknesses with lower Ir loading, reducing iridium utilization at 70% LHV from 0.42 to 0.075 gIr kW-1 compared to commercial IrO2/TiO2. The identification of the Ir@IrO(OH)x/TiO2 OER catalyst resulted from extensive HAADF-EDX microscopic analysis, operando XAS, and online ICP-MS analysis of 30-80 wt % Ir/TiO2 materials. These analyses established correlations among Ir weight loading, electrode electrical conductivity, electrochemical stability, and Ir mass-based OER activity. The activated Ir@IrO(OH)x/TiO2 catalyst-support system demonstrated an exceptionally stable morphology of supported core-shell particles, suggesting strong catalyst-support interactions (CSIs) between nanoparticles and crystalline oxide facets. Operando XAS analysis revealed the reversible evolution of significantly contracted Ir-O bond motifs with enhanced covalent character, conducive to the formation of catalytically active electrophilic OI- ligand species. These findings indicate that atomic Ir surface dissolution generates Ir lattice vacancies, facilitating the emergence of electrophilic OI- species under OER conditions, while CSIs promote the reversible contraction of Ir-O distances, reforming electrophilic OI- and enhancing both catalytic activity and stability.

Oxyanion Engineering on RuO2 for Efficient Proton Exchange Membrane Water Electrolysis

In acidic proton exchange membrane water electrolysis (PEMWE), the anode oxygen evolution reaction (OER) catalysts rely heavily on the expensive and scarce iridium-based materials. Ruthenium dioxide (RuO2) with lower price and higher OER activity, has been explored for the similar task, but has been restricted by the poor stability. Herein, we developed an anion modification strategy to improve the OER performance of RuO2 in acidic media. The designed multicomponent catalyst based on sulfate anchored on RuO2/MoO3 displays a low overpotential of 190 mV at 10 mA cm-2 and stably operates for 500 hours with a very low degradation rate of 20 μV h-1 in acidic electrolyte. When assembled in a PEMWE cell, this catalyst as an anode shows an excellent stability at 500 mA cm-2 for 150 h. Experimental and theoretical results revealed that MoO3 could stabilize sulfate anion on RuO2 surface to suppress its leaching during OER. Such MoO3-anchored sulfate not only reduces the formation energy of *OOH intermediate on RuO2, but also impedes both the surface Ru and lattice oxygen loss, thereby achieving the high OER activity and exceptional durability.

Stability of electrocatalytic OER: from principle to application

Hydrogen energy, derived from the electrolysis of water using renewable energy sources such as solar, wind, and hydroelectric power, is considered a promising form of energy to address the energy crisis. However, the anodic oxygen evolution reaction (OER) poses limitations due to sluggish kinetics. Apart from high catalytic activity, the long-term stability of electrocatalytic OER has garnered significant attention. To date, several research studies have been conducted to explore stable electrocatalysts for the OER. A comprehensive review is urgently warranted to provide a concise overview of the recent advancements in the electrocatalytic OER stability, encompassing both electrocatalyst and device developments. This review aims to succinctly summarize the primary factors influencing OER stability, including morphological/phase change and electrocatalyst dissolution, as well as mechanical detachment, alongside chemical, mechanical, and operational degradation observed in devices. Furthermore, an overview of contemporary approaches to enhance stability is provided, encompassing electrocatalyst design (structural regulation, protective layer coating, and stable substrate anchoring) and device optimization (bipolar plates, gas diffusion layers, and membranes). Hopefully, more attention will be paid to ensuring the stable operation of electrocatalytic OER and the future large-scale water electrolysis applications. This review presents design principles aimed at addressing challenges related to the stability of electrocatalytic OER.

Ultrathin and Conformal Depletion Layer of Core/Shell Heterojunction Enables Efficient and Stable Acidic Water Oxidation

Ru-based electrocatalysts hold great promise for developing affordable proton exchange membrane (PEM) electrolyzers. However, the harsh acidic oxidative environment of the acidic oxygen evolution reaction (OER) often causes undesirable overoxidation of Ru active sites and subsequent serious activity loss. Here, we present an ultrathin and conformal depletion layer attached to the Schottky heterojunction of core/shell RuCo/RuCoOx that not only maximizes the availability of active sites but also improves its durability and intrinsic activity for acidic OER. Operando synchrotron characterizations combined with theoretical calculations elucidate that the lattice strain and charge transfer induced by Schottky heterojunction substantially regulate the electronic structures of active sites, which modulates the OER pathway and suppresses the overoxidation of Ru species. Significantly, the closed core/shell architecture of the RuCo/RuCoOx ensures the structure integrity of the Schottky heterojunction under acidic OER conditions. As a result, the core/shell RuCo/RuCoOx Schottky heterojunction exhibits an unprecedented durability up to 250 0 h at 10 mA cm-2 with an ultralow overpotential of ∼170 mV at 10 mA cm-2 in 0.5 M H2SO4. The RuCo/RuCoOx catalyst also demonstrates superior durability in a proton exchange membrane (PEM) electrolyzer, showcasing the potential for practical applications.

Manipulating d-Band Center of Nickel by Single-Iodine-Atom Strategy for Boosted Alkaline Hydrogen Evolution Reaction

Ni-based electrocatalysts have been predicted as highly potential candidates for hydrogen evolution reaction (HER); however, their applicability is hindered by an unfavorable d-band energy level (Ed). Moreover, precise d-band structural engineering of Ni-based materials is deterred by appropriative synthesis methods and experimental characterization. Herein, we meticulously synthesize a special single-iodine-atom structure (I-Ni@C) and characterize the Ed manipulation via resonant inelastic X-ray scattering (RIXS) spectroscopy to fill this gap. The complex catalytic mechanism has been elucidated via synchrotron radiation-based multitechniques (SRMS) including X-ray absorption fine structure (XAFS), in situ synchrotron radiation-based Fourier transform infrared (SR-FTIR) spectroscopy, and near ambient pressure X-ray photoelectron spectroscopy (NAP-XPS). In particular, RIXS is innovatively applied to reveal the precise regulation of Ni Ed of I-Ni@C. Consequently, the role of such single-iodine-atom strategy is confirmed to not only facilitate the moderate Ed of the Ni site for balancing the adsorption/desorption capacities of key intermediates but also act as a bridge to enhance the electronic interaction between Ni and the carbon shell for forming a localized polarized electric field conducive to H2O dissociation. As a result, I-Ni@C exhibits an enhanced alkaline hydrogen evolution performance with an overpotential of 78 mV at 10 mA/cm2 and superior stability, surpassing the majority of the reported Ni-based catalysts. Overall, this study has managed to successfully tailor the d-band center of materials from the SRMS perspective, which has crucial implications for nanotechnology, chemistry, catalysis, and other fields.

Nest-Scheme RuIrLa Nanocrystals by NP-to-NP Oriented Assembly: Coherent Strain Fields-Driven Band Structure Splitting for Efficient Acidic Water Oxidation

Atomic substructure engineering provides new opportunities for the designing newly and efficient catalysts with diverse atom ensembles, trimmed electron bands, and way-out coordination environments, creating unique contributing to concertedly catalyze water oxidation, which is of great significance for proton exchange membrane water electrolysis (PEMWE). Herein, nest-scheme RuIrLa nanocrystals with dense coherent interfaces as built-in substructures are firstly fabricated by using commercial ZnO particles as acid-removable templates, through a La-stabilized coherent epitaxial growth of nanoparticles (NPs). The obtained nests exhibit a low overpotential of 198 mV at 10 mA cm-2, and the RuIrLa||Pt/C module equipped in PEMWE operates stably at a cell voltage potential of 1.69 V at 100 mA cm-2 in 0.5 M H2SO4 for 55 h, which is far beyond the current IrO2||Pt/C. Within the nests, the position at the interface shows high tensile/compressive strain, significantly reducing the OER activation energy. More importantly, the La termination-stabilized coherent interfaces within the nests creates a unique self-healing process for the outstanding long-term stability. This work provides a promising substructure engineering to develop efficient catalysts with abundant substructures, such as coherent interfaces, dislocations, or grain boundaries, thereby realizing concerted improvement of activity and durability toward water oxidation.

Ligand-induced hollow binary metal-organic framework derived Fe-doped cobalt-carbon nanomaterials for oxygen evolution

There is significant anticipation for high-efficiency and cost-effective non-precious metal-based catalysts to advance the industrial application of the anodic oxygen evolution reaction (OER) for hydrogen production. This study introduces an efficient strategy that utilizes ligand-induced metal-organic framework (MOF) building blocks for the synthesis of hollow binary zeolitic imidazolate frameworks 67 (ZIF-67) and Prussian blue analogues (PBAs) (ZIF-67@PBA) heterostructures through a hybrid MOF-on-MOF approach. Manipulating the Co2+/Zn2+ ratio in the precursor ZIF-67 allows for the convenient synthesis of the final product, denoted as CoxFe-ZP, after pyrolysis, where the inclusion of Zn effectively modulates the distribution of Co in the catalyst. The resulting CoxFe-ZP catalysts exhibit a positive synergistic effect between hollow graphitic carbon nanomaterials and Fe-doped Co nanoparticles. The optimal Co0.3Fe-ZP catalyst demonstrates satisfactory OER performance, achieving an overpotential of 302 mV at 10 mA cm-2 and a small Tafel slope of 60.0 mV dec-1. Further analysis of the activation energy confirms that the enhanced OER activity of Co0.3Fe-ZP can be reasonably attributed to the combined influence of its morphology and composition. This study demonstrates a ligand-induced method for examining the morphology and electrochemical properties of grown binary MOF-on-MOF heterostructures for OER applications.

Ruthenium Single-Atom Modulated Protonated Iridium Oxide for Acidic Water Oxidation in Proton Exchange Membrane Electrolysers

Proton exchange membrane water electrolysers promise to usher in a new era of clean energy, but they remain a formidable obstacle in designing active and durable electrocatalysts for the acidic oxygen evolution reaction (OER). In this study, a protonated iridium oxide embedded with single-atom dispersed ruthenium atoms (H3.8Ir1- xRuxO4) that demonstrates exceptional activity and stability in acidic water oxidation is introduced. The single Ru dopants favorably induce localized oxygen vacancies in the Ir─O lattice, synergistically strengthening the adsorption of OOH* intermediates and enhancing the intrinsic OER activity. In addition, the preferential oxidation of Ru and the electronegativity of the oxygen vacancies significantly stabilize the Ir─O active sites, improving the OER stability. Consequently, the H3.8Ir1─ xRuxO4 catalyst shows an overpotential of 255 mV at 10 mA cm-2 and displays exceptional catalytic endurance in acidic electrolytes, surpassing 1100 h, representing a remarkable one-order-of-magnitude increase in stability compared to that of pristine H3.8IrO4. A proton exchange membrane electrolyser utilizing the H3.8Ir1- xRuxO4 catalyst as an anode exhibits stable performance for more than 1280 h under a high current density of 2 A cm-2.

Enhanced catalytic performance through a single-atom preparation approach: a review on ruthenium-based catalysts

The outstanding catalytic properties of single-atom catalysts (SACs) stem from the maximum atom utilization and unique quantum size effects, leading to ever-increasing research interest in SACs in recent years. Ru-based SACs, which have shown excellent catalytic activity and selectivity, have been brought to the frontier of the research field due to their lower cost compared with other noble catalysts. The synthetic approaches for preparing Ru SACs are rather diverse in the open literature, covering a wide range of applications. In this review paper, we attempt to disclose the synthetic approaches for Ru-based SACs developed in the most recent years, such as defect engineering, coordination design, ion exchange, the dipping method, and electrochemical deposition etc., and discuss their representative applications in both electrochemical and organic reaction fields, with typical application examples given of: Li-CO2 batteries, N2 reduction, water splitting and oxidation of benzyl alcohols. The mechanisms behind their enhanced catalytic performance are discussed and their structure-property relationships are revealed in this review. Finally, future prospects and remaining unsolved issues with Ru SACs are also discussed so that a roadmap for the further development of Ru SACs is established.

Supported IrO2 Nanocatalyst with Multilayered Structure for Proton Exchange Membrane Water Electrolysis

The design of a low-iridium-loading anode catalyst layer with high activity and durability is a key challenge for a proton exchange membrane water electrolyzer (PEMWE). Here, the synthesis of a novel supported IrO2 nanocatalyst with a tri-layered structure, dubbed IrO2@TaOx@TaB that is composed of ultrasmall IrO2 nanoparticles anchored on amorphous TaOx overlayer of TaB nanorods is reported. The composite electrocatalyst shows great activity and stability toward the oxygen evolution reaction (OER) in acid, thanks to its dual-interface structural feature. The electronic interaction in IrO2/TaOx interface can regulate the coverage of surface hydroxyl groups, the Ir3+/ Ir4+ ratio, and the redox peak potential of IrO2 for enhancing OER activity, while the dense TaOx overlayer can prevent further oxidation of TaB substrate and stabilize the IrO2 catalytic layers for improving structural stability during OER. The IrO2@TaOx@TaB can be used to fabricate an anode catalyst layer of PEMWE with an iridium-loading as low as 0.26 mg cm-2. The low-iridium-loading PEMWE delivers high current densities at low cell voltages (e.g., 3.9 A cm-2@2.0 V), and gives excellent activity retention for more than 1500 h at 2.0 A cm-2 current density.

Atomic-Level Observation of Potential-Dependent Variations at the Surface of an Oxide Catalyst during Oxygen Evolution Reaction

Understanding the intricate details of the surface atomic structure and composition of catalysts during the oxygen evolution reaction (OER) is crucial for developing catalysts with high stability in water electrolyzers. While many notable studies highlight surface amorphization and reconstruction, systematic analytical tracing of the catalyst surface as a function of overpotential remains elusive. Heteroepitaxial (001) films of chemically stable and lattice-oxygen-inactive LaCoO3 are thus utilized as a model catalyst to demonstrate a series of atomic-resolution observations of the film surface at different anodic potentials. The first key finding is that atoms at the surface are fairly dynamic even at lower overpotentials. Angstrom-scale atomic displacements within the perovskite framework are identified below a certain potential level. Another noteworthy feature is that amorphization (or paracrystallization) with no long-range order is finally induced at higher overpotentials. In particular, surface analyses consistently support that the oxidation of lattice oxygen is coupled with amorphous phase formation at the high potentials. Theoretical calculations also reveal an upward shift of oxygen 2p states toward the Fermi level, indicating enhanced lattice oxygen activation when atom displacement occurs more extensively. This study emphasizes that the degradation behavior of OER catalysts can distinctively vary depending on the overpotential level.

Advances in Noble Metal Electrocatalysts for Acidic Oxygen Evolution Reaction: Construction of Under-Coordinated Active Sites

Renewable energy-driven proton exchange membrane water electrolyzer (PEMWE) attracts widespread attention as a zero-emission and sustainable technology. Oxygen evolution reaction (OER) catalysts with sluggish OER kinetics and rapid deactivation are major obstacles to the widespread commercialization of PEMWE. To date, although various advanced electrocatalysts have been reported to enhance acidic OER performance, Ru/Ir-based nanomaterials remain the most promising catalysts for PEMWE applications. Therefore, there is an urgent need to develop efficient, stable, and cost-effective Ru/Ir catalysts. Since the structure-performance relationship is one of the most important tools for studying the reaction mechanism and constructing the optimal catalytic system. In this review, the recent research progress from the construction of unsaturated sites to gain a deeper understanding of the reaction and deactivation mechanism of catalysts is summarized. First, a general understanding of OER reaction mechanism, catalyst dissolution mechanism, and active site structure is provided. Then, advances in the design and synthesis of advanced acidic OER catalysts are reviewed in terms of the classification of unsaturated active site design, i.e., alloy, core-shell, single-atom, and framework structures. Finally, challenges and perspectives are presented for the future development of OER catalysts and renewable energy technologies for hydrogen production.

Capillary-Driven Separate Gas-Liquid Transport: Alleviating Mass Transport Losses for Efficient Hydrogen Evolution

Developing earth-abundant transition metal electrodes with high activity and durability is crucial for efficient and cost-effective hydrogen production. However, numerous studies in the hydrogen evolution reaction (HER) primarily focus on improving the inherent activity of catalysts, and the critical influence of gas-liquid countercurrent transport behavior is often overlooked. In this study, we introduce the concept of separate-path gas-liquid transport to alleviate mass transport losses for the HER by developing a novel hierarchical porous Ni-doped cobalt phosphide electrode (CoNix-P@Ni). The CoNix-P@Ni electrodes with abundant microvalleys and crack structures facilitate the gas-liquid cotransport by separating the bubble release and water supply paths. Visualization and numerical simulation results demonstrate that cracks primarily serve as water supply paths, with capillary pressure facilitating the transport of water from the cracks to the microvalleys. This process ensures the continuous wetting of electrolytes in the electrode, reduces hydrogen supersaturation near the active site, and increases hydrogen transport flux to the microvalleys for accelerating bubble growth. Additionally, the microvalleys act as preferential sites for bubble evolution, preventing bubble coverage on other active sites. By regulating the amount of nickel, the CoNi1-P@Ni electrode exhibited the smallest and densest microvalleys and cracks, achieving superior HER performance with an overpotential of 51 mV at 10 mA cm-2. The results offer a promising direction for constructing high-performance HER electrodes.

Ink-based additive manufacturing for electrochemical applications

Additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has drawn substantial attention in recent decades due to its efficiency and precise control in part fabrication. The limitations of conventional fabrication processes, especially regarding geometry complexity, supply chain, and environmental impact, have prompted the exploration of diverse AM technologies in electrochemistry. Especially, three ink-based AM techniques, binder jet printing (BJP), direct ink writing (DIW), and Inkjet Printing (IJP), have been extensively applied by numerous research teams to produce electrodes, catalyst scaffolds, supercapacitors, batteries, etc. BJP's versatility in utilizing a wide range of materials as powder feedstock promotes its potential for various electrode and battery applications. DIW and IJP stand out for their ability to handle multi-material manufacturing tasks and deliver high printing resolution. To capture recent advancements in this field, we present a comprehensive review of the applications of BJP, DIW, and IJP techniques in fabricating electrochemical devices and components. This review intends to provide an overview of the process-structure-property relationship in electrochemical materials and components across diverse applications manufactured using AM techniques. We delve into how the significantly improved design freedom over the structure offered by these ink-based AM techniques highlights the performance of electrochemical products. Moreover, we highlight their advantages in terms of material compatibility, geometry control, and cost-effectiveness. In specific cases, we also compare the performance of electrochemical components fabricated using AM and conventional manufacturing methods. Finally, we conclude this review article by offering some insights into the future development in this research field.

Self-etching assembly of designed NiFeMOF nanosheet arrays as high-efficient oxygen evolution electrocatalyst for water splitting

2D metal-organic frameworks (MOFs) have emerged as potential candidates for electrocatalytic oxygen evolution reactions (OER) due to their inherent properties like abundant coordination unsaturated active sites and efficient charge transfer. Herein, a versatile and massively synthesizable self-etching assembly strategy wherein nickel-iron foam (NFF) acts as a substrate and a metal ion source. Specifically, by etching the nickel-iron foam (NFF) surface using ligands and solvents, Ni/Fe metal ions are activated and subsequently reacted under hydrothermal conditions, resulting in the formation of self-supporting nanosheet arrays, eliminating the need for external metal salts. The obtained 33 % NiFeMOF/NFF exhibits remarkable OER performance with ultra-low overpotentials of 188/231 mV at 10/100 mA cm-2, respectively, outperforming most recently reported catalysts. Besides, the built 33 % NiFeMOF/NFF(+)||Pt/C(-) electrolyzer presents low cell voltages of 1.55/1.83 V at 10/100 mA cm-2, superior to the benchmark RuO2 (+)||Pt/C(-), implying good industrialization prospects. The excellent catalytic activity stems from the modulation of the electronic spin state of the Ni active site by the introduction of Fe, which facilitates the adsorption process of oxygen-containing intermediates and thus enhances the OER activity. This innovative approach offers a promising pathway for commercial-scale sustainable energy solutions.

Water-hydroxide trapping in cobalt tungstate for proton exchange membrane water electrolysis

The oxygen evolution reaction is the bottleneck to energy-efficient water-based electrolysis for the production of hydrogen and other solar fuels. In proton exchange membrane water electrolysis (PEMWE), precious metals have generally been necessary for the stable catalysis of this reaction. In this work, we report that delamination of cobalt tungstate enables high activity and durability through the stabilization of oxide and water-hydroxide networks of the lattice defects in acid. The resulting catalysts achieve lower overpotentials, a current density of 1.8 amperes per square centimeter at 2 volts, and stable operation up to 1 ampere per square centimeter in a PEMWE system at industrial conditions (80°C) at 1.77 volts; a threefold improvement in activity; and stable operation at 1 ampere per square centimeter over the course of 600 hours.

Ru/Ir-Based Electrocatalysts for Oxygen Evolution Reaction in Acidic Conditions: From Mechanisms, Optimizations to Challenges

The generation of green hydrogen by water splitting is identified as a key strategic energy technology, and proton exchange membrane water electrolysis (PEMWE) is one of the desirable technologies for converting renewable energy sources into hydrogen. However, the harsh anode environment of PEMWE and the oxygen evolution reaction (OER) involving four-electron transfer result in a large overpotential, which limits the overall efficiency of hydrogen production, and thus efficient electrocatalysts are needed to overcome the high overpotential and slow kinetic process. In recent years, noble metal-based electrocatalysts (e.g., Ru/Ir-based metal/oxide electrocatalysts) have received much attention due to their unique catalytic properties, and have already become the dominant electrocatalysts for the acidic OER process and are applied in commercial PEMWE devices. However, these noble metal-based electrocatalysts still face the thorny problem of conflicting performance and cost. In this review, first, noble metal Ru/Ir-based OER electrocatalysts are briefly classified according to their forms of existence, and the OER catalytic mechanisms are outlined. Then, the focus is on summarizing the improvement strategies of Ru/Ir-based OER electrocatalysts with respect to their activity and stability over recent years. Finally, the challenges and development prospects of noble metal-based OER electrocatalysts are discussed.

Bicontinuous RuO2 nanoreactors for acidic water oxidation

Improving activity and stability of Ruthenium (Ru)-based catalysts in acidic environments is eager to replace more expensive Iridium (Ir)-based materials as practical anode catalyst for proton-exchange membrane water electrolyzers (PEMWEs). Here, a bicontinuous nanoreactor composed of multiscale defective RuO2 nanomonomers (MD-RuO2-BN) is conceived and confirmed by three-dimensional tomograph reconstruction technology. The unique bicontinuous nanoreactor structure provides abundant active sites and rapid mass transfer capability through a cavity confinement effect. Besides, existing vacancies and grain boundaries endow MD-RuO2-BN with generous low-coordination Ru atoms and weakened Ru-O interaction, inhibiting the oxidation of lattice oxygen and dissolution of high-valence Ru. Consequently, in acidic media, the electron- and micro-structure synchronously optimized MD-RuO2-BN achieves hyper water oxidation activity (196 mV @ 10 mA cm-2) and an ultralow degradation rate of 1.2 mV h-1. A homemade PEMWE using MD-RuO2-BN as anode also conveys high water splitting performance (1.64 V @ 1 A cm-2). Theoretical calculations and in-situ Raman spectra further unveil the electronic structure of MD-RuO2-BN and the mechanism of water oxidation processes, rationalizing the enhanced performance by the synergistic effect of multiscale defects and protected active Ru sites.

Self-Supported WO3@RuO2 Nanowires for Electrocatalytic Acidic Water Oxidation

Developing catalysts with high catalytic activity and stability in acidic media is crucial for advancing hydrogen production in proton exchange membrane water electrolyzers (PEMWEs). To this end, a self-supported WO3@RuO2 nanowire structure was grown in situ on a titanium mesh using hydrothermal and ion-exchange methods. Despite a Ru loading of only 0.098 wt %, it achieves an overpotential of 246 mV for the oxygen evolution reaction (OER) at a current density of 10 mA·cm-2 in acidic 0.5 M H2SO4 while maintaining excellent stability over 50 h, much better than that of the commercial RuO2. After the establishment of the WO3@RuO2 heterostructure, a reduced overpotential of the rate-determining step from M-O* to M-OOH* is confirmed by the DFT calculation. Meanwhile, its enhanced OER kinetics are also greatly improved by this self-supported system in the absence of the organic binder, leading to a reduced interface resistance between active sites and electrolytes. This work presents a promising approach to minimize the use of noble metals for large-scale PEMWE applications.

Unique activity of a Keggin POM for efficient heterogeneous electrocatalytic OER

Polyoxometalates (POMs) have been well studied and explored in electro/photochemical water oxidation catalysis for over a decade. The high solubility of POMs in water has limited its use in homogeneous conditions. Over the last decade, different approaches have been used for the heterogenization of POMs to exploit their catalytic properties. This study focused on a Keggin POM, K6[CoW12O40], which was entrapped in a sol-gel matrix for heterogeneous electrochemical water oxidation. Its entrapment in the sol-gel matrix enables it to catalyze the oxygen evolution reaction at acidic pH, pH 2.0. Heterogenization of POMs using the sol-gel method aids in POM's recyclability and structural stability under electrochemical conditions. The prepared sol-gel electrode is robust and stable. It achieved electrochemical water oxidation at a current density of 2 mA/cm2 at a low overpotential of 300 mV with a high turnover frequency (TOF) of 1.76 [mol O2 (mol Co)-1s-1]. A plausible mechanism of the electrocatalytic process is presented.

Catalytic Activity and Electrochemical Stability of Ru1-xMxO2 (M = Zr, Nb, Ta): Computational and Experimental Study of the Oxygen Evolution Reaction

We use computations and experiments to determine the effect of substituting zirconium, niobium, and tantalum within rutile RuO2 on the structure, oxygen evolution reaction (OER) mechanism and activity, and electrochemical stability. Calculated electronic structures altered by Zr, Nb, and Ta show surface regions of electron density depletion and accumulation, along with anisotropic lattice parameter shifts dependent on the substitution site, substituent, and concentration. Consistent with theory, X-ray photoelectron spectroscopy experiments show shifts in binding energies of O-2s, O-2p, and Ru-4d peaks due to the substituents. Experimentally, the substituted materials showed the presence of two phases with a majority phase that contains the metal substituent within the rutile phase and a second, smaller-percentage RuO2 phase. Our experimental analysis of OER activity shows Zr, Nb, and Ta substituents at 12.5 atom % induce lower activity relative to RuO2, which agrees with computing the average of all sites; however, Zr and Ta substitution at specific sites yields higher theoretical OER activity than RuO2, with Zr substitution suggesting an alternative OER mechanism. Metal dissolution predictions show the involvement of cooperative interactions among multiple surface sites and the electrolyte. Zr substitution at specific sites increases activation barriers for Ru dissolution, however, with Zr surface dissolution rates comparable to those of Ru. Experimental OER stability analysis shows lower Ru dissolution from synthesized RuO2 and Zr-substituted RuO2 compared to commercial RuO2 and comparable amounts of Zr and Ru dissolved from Zr-substituted RuO2, aligned with our calculations.

Sub-10-nm-sized Au@AuxIr1-x metal-core/alloy-shell nanoparticles as highly durable catalysts for acidic water splitting

The absence of efficient and durable catalysts for oxygen evolution reaction (OER) is the main obstacle to hydrogen production through water splitting in an acidic electrolyte. Here, we report a controllable synthesis method of surface IrOx with changing Au/Ir compositions by constructing a range of sub-10-nm-sized core-shell nanocatalysts composed of an Au core and AuxIr1-x alloy shell. In particular, Au@Au0.43Ir0.57 exhibits 4.5 times higher intrinsic OER activity than that of the commercial Ir/C. Synchrotron X-ray-based spectroscopies, electron microscopy and density functional theory calculations revealed a balanced binding of reaction intermediates with enhanced activity. The water-splitting cell using a load of 0.02 mgIr/cm2 of Au@Au0.43Ir0.57 as both anode and cathode can reach 10 mA/cm2 at 1.52 V and maintain activity for at least 194 h, which is better than the cell using the commercial couple Ir/C‖Pt/C (1.63 V, 0.2 h).

Porous Tellurium-Doped Ruthenium Dioxide Nanotubes for Enhanced Acidic Water Oxidation

Electrocatalysts with high activity and durability for acidic oxygen evolution reaction (OER) play a crucial role in achieving cost-effective hydrogen production via proton exchange membrane water electrolysis. A novel electrocatalyst, Te-doped RuO2 (Te-RuO2) nanotubes, synthesized using a template-directed process, which significantly enhances the OER performance in acidic media is reported. The Te-RuO2 nanotubes exhibit remarkable OER activity in acidic media, requiring an overpotential of only 171 mV to achieve an anodic current density of 10 mA cm-2. Furthermore, they maintain stable chronopotentiometric performance under 10 mA cm-2 in acidic media for up to 50 h. Based on the experimental results and density functional calculations, this significant improvement in OER performance to the synergistic effect of large specific surface area and modulated electronic structure resulting from the doping of Te cations is attributed.

Highly Crystalline Iridium-Nickel Nanocages with Subnanopores for Acidic Bifunctional Water Splitting Electrolysis

Developing efficient bifunctional materials is highly desirable for overall proton membrane water splitting. However, the design of iridium materials with high overall acidic water splitting activity and durability, as well as an in-depth understanding of the catalytic mechanism, is challenging. Herein, we successfully developed subnanoporous Ir3Ni ultrathin nanocages with high crystallinity as bifunctional materials for acidic water splitting. The subnanoporous shell enables Ir3Ni NCs optimized exposure of active sites. Importantly, the nickel incorporation contributes to the favorable thermodynamics of the electrocatalysis of the OER after surface reconstruction and optimized hydrogen adsorption free energy in HER electrocatalysis, which induce enhanced intrinsic activity of the acidic oxygen evolution reaction (OER) and hydrogen evolution reaction (HER). Together, the Ir3Ni nanocages achieve 3.72 A/mgIr(η=350 mV) and 4.47 A/mgIr(η=40 mV) OER and HER mass activity, which are 18.8 times and 3.3 times higher than that of commercial IrO2 and Pt, respectively. In addition, their highly crystalline identity ensures a robust nanostructure, enabling good catalytic durability during the oxygen evolution reaction after surface oxidation. This work provides a new revenue toward the structural design and insightful understanding of metal alloy catalytic mechanisms for the bifunctional acidic water splitting electrocatalysis.

Locking the lattice oxygen in RuO2 to stabilize highly active Ru sites in acidic water oxidation

Ruthenium dioxide is presently the most active catalyst for the oxygen evolution reaction (OER) in acidic media but suffers from severe Ru dissolution resulting from the high covalency of Ru-O bonds triggering lattice oxygen oxidation. Here, we report an interstitial silicon-doping strategy to stabilize the highly active Ru sites of RuO2 while suppressing lattice oxygen oxidation. The representative Si-RuO2-0.1 catalyst exhibits high activity and stability in acid with a negligible degradation rate of ~52 μV h-1 in an 800 h test and an overpotential of 226 mV at 10 mA cm-2. Differential electrochemical mass spectrometry (DEMS) results demonstrate that the lattice oxygen oxidation pathway of the Si-RuO2-0.1 was suppressed by ∼95% compared to that of commercial RuO2, which is highly responsible for the extraordinary stability. This work supplied a unique mentality to guide future developments on Ru-based oxide catalysts' stability in an acidic environment.