Inexpensive and robust iron-based electrode substrates for water electrolysis and energy storage

The instability of iron under anodic conditions makes iron-based electrode substrates unsuitable for alkaline electrolyzers and rechargeable alkaline batteries. Therefore, significantly more expensive substrates such as nickel foam or sintered nickel are used. Nickel adds a significant cost to electrolysis and energy storage systems. We show that iron substrates can be stabilized using a unique protective thermal coating. These coatings can also yield some of the most electrocatalytically active electrodes in addition to showing no notable change in performance even after 1500 h of anodic polarization. Besides sintered iron, low-carbon steel mesh can be stabilized similarly. Low-carbon steel protected by a thin layer of lithium-doped cobalt spinel was found to be an excellent current collector for positive nickel hydroxide electrodes in alkaline batteries. Thus, surface-modified iron substrates, 40 times less expensive than nickel, are promising for lowering the material costs of alkaline water electrolyzers and rechargeable alkaline batteries.