This study targets one of the grand challenges of electrochemical hydrogen production: a durable and cost-effective oxygen-evolution catalyst. We present a thin-film composite electrode with a unique morphology and an ultralow loading of iridium that has extraordinary electrocatalytic properties. This is accomplished by the electrochemical growth of a defined, high-surface-area titanium oxide nanotubular film, followed by the nitridation and effective immobilization of iridium nanoparticles. The applicative relevance of this production process is justified by a high oxygen-evolution reaction (OER) activity and high stability. Enhanced OER performance is due to the strong metal–support interaction (SMSI). The high durability is achieved by self-passivation of the titanium oxynitride (TiON) surface layer with TiO2, which in addition also effectively embeds the Ir nanoparticles while still keeping them electrically wired. An additional contribution to the enhanced durability comes from the nitrogen atoms, which according to our density functional theory (DFT) calculations reduce the tendency of the Ir nanoparticles to grow. Materials are analyzed by advanced electrochemical characterization techniques. Namely, the entire process of the TiON–Ir electrode’s preparation and the electrochemical evaluation can be tracked with scanning electron microscopy, X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS) at identical locations. In general, the experimental approach allows for the unique morphological, structural, and compositional insights into the preparation and electrocatalytic performance of thin films, making it useful also outside electrocatalysis applications.

The rational design of electrochemical oxygen evolution reaction (OER) electrocatalyst is essential for the development of efficient and sustainable electrochemical energy conversion, storage and electrolysis applications. One of the remaining limitations of the low‐temperature electrolyzers is the large amounts of highly scarce and expensive iridium used as the OER electrocatalysts. This could be solved by applying much smaller amounts of iridium on efficient and stable support. Here we present a very promising functionality of titanium oxynitride (TiONx) high‐surface‐area support that effectively disperses the iridium nanoparticles, exhibits good intrinsic electrical conductivity and stability and thus promises efficient reduction of the noble‐metal loading in electrolyzers gas diffusion electrodes. The new nanocomposite made of approximately 3 nm‐sized iridium nanoparticles finely dispersed on TiONx support is produced using a novel synthetic route. Extensive characterization shows that the new composites exhibit an electronic interaction with the support and, ultimately, a high OER performance in acidic media.

The development of affordable, low-iridium-loading, scalable, active, and stable catalysts for the oxygen-evolution reaction (OER) is a requirement for the commercialization of proton-exchange membrane water electrolyzers (PEMWEs). However, the synthesis of high-performance OER catalysts with minimal use of the rare and expensive element Ir is very challenging and requires the identification of electrically conductive and stable high-surface-area support materials. We developed a synthesis procedure for the production of large quantities of a nanocomposite powder containing titanium oxynitride (TiON x ) and Ir. The catalysts were synthesized with an anodic oxidation process followed by detachment, milling, thermal treatment, and the deposition of Ir nanoparticles. The anodization time was varied to grow three different types of nanotubular structures exhibiting different lengths and wall thicknesses and thus a variety of properties. A comparison of milled samples with different degrees of nanotubular clustering and morphology retention, but with identical chemical compositions and Ir nanoparticle size distributions and dispersions, revealed that the nanotubular support morphology is the determining factor governing the catalyst's OER activity and stability. Our study is supported by various state-of-the-art materials' characterization techniques, like X-ray photoelectron spectroscopy, scanning and transmission electron microscopies, Xray powder diffraction and absorption spectroscopy, and electrochemical cyclic voltammetry. Anodic oxidation proved to be a very suitable way to produce high-surface-area powder-type catalysts as the produced material greatly outperformed the IrO 2 benchmarks as well as the Ir-supported samples on morphologically different TiON x from previous studies. The highest activity was achieved for the sample prepared with 3 h of anodization, which had the most appropriate morphology for the effective removal of oxygen bubbles.