Nickel-plated copper foam as a scalable catalyst for hydrogen generation in alkaline media

Abstract The development of effective, affordable catalysts for water splitting is essential to achieving sustainable hydrogen production. Herein, we report the electrochemical synthesis of nickel-plated copper foam (Ni–Cu foam) as a scalable and admirable catalyst for water splitting in alkaline media. The copper foam substrate offers a three-dimensional (3D) porous structure that increases surface area and promotes efficient mass transport, whereas the nickel layer acts as the active site for the hydrogen evolution reaction (HER). The galvanostatic electrochemical deposition process enables precise control over nickel layer thickness, ensuring uniform coverage and optimal catalyst performance. Electrochemical evaluations reveal that the Ni–Cu foam catalyst exhibits an overpotential of 260 mV towards HER in 1 M KOH and a lower Tafel slope, indicating favorable reaction kinetics. Furthermore, the catalyst demonstrates good stability, retaining over 83% of its activity after 15 h of continuous operation. The synergistic interaction between the nickel coating and the copper foam substrate enhances catalytic performance. This study highlights the potential of electrochemically synthesized Ni–Cu foam as a scalable and efficient catalyst for water electrolysis, paving the way for practical applications in renewable energy systems.