Fabrication of nickel electrode coatings by combination of atmospheric and suspension plasma spray processes

Three-dimensional electrode coatings for hydrogen production manufactured by combined atmospheric and suspension plasma spray

“…com, USA) were used to coat Inconel 600 substrate coupons with the surface dimensions of 25 × 25 mm 2 . The particle size distribution of the starting powders was determined to be between 45 and 90 μm with D50 of 69 μm and 100 nm to 11 μm with D50 of 730 nm for nickel and nickel oxide, respectively, using a laser diffraction particle size analyzer (Malvern Instruments Ltd., England) [17].…”

“…Table 2 shows the plasma spraying parameters used in APS and SPS coating processes. The parameters were selected based on our previous results [14,17]. The samples were named according to Table 3 throughout this work.…”

“…Among various thermal spraying methods that have been used to manufacture nickel-based electrodes, atmospheric plasma spray (APS) has shown its capability in development of micron and nano-structured active electrode coatings for the HER [14][15][16][17][18][19]. In this process, the sprayed particles melt and accelerate towards the substrate within the high temperature plasma jet.…”

“…In our previous work, it was shown that electrodes with high activities could be developed by combination of the two APS and SPS methods [17,18]. In this combined method, few SPS layers were deposited on already APS coated electrodes.…”

“…The superior electrochemical properties of the electrodes were mainly related to their large effective surface areas with unique hierarchical microstructures. The dual micron/submicron-sized surface features enhanced the electrode activity by promoting surface accessibility to the electrolyte, providing more reaction sites for hydrogen adsorption and facilitating hydrogen bubble release from the surface [17,18].…”