Mn-Dopant Differentiating the Ru and Ir Oxidation States in Catalytic Oxides Toward Durable Oxygen Evolution Reaction in Acidic Electrolyte

Highly Efficient and Durable Anode Catalyst Layer Constructed with Deformable Hollow IrOx Nanospheres in Low-Iridium PEM Water Electrolyzer

Reducing iridium packing density (gIr cm-3 electrode) represents a critical pathway to lower geometric Ir loading in proton exchange membrane water electrolyzers (PEMWEs), yet conventional approaches often cause performance issues of anode catalyst layer due to decreased structural stability and limited electron/mass transport efficiency. Here, we present deformable hollow IrOx nanospheres (dh-IrOx) as a structural-engineered catalyst architecture that achieves an ultralow Ir packing density (20% of conventional IrO2 nanoparticle-based electrodes) while maintaining high catalytic activity and durability at reduced Ir loadings. Scalable synthesis of dh-IrOx via a hard-template method-featuring precise SiO2 nanosphere templating and conformal Ir(OH)3 coating-enables batch production of tens of grams. Through cavity dimension and shell thickness optimization, dh-IrOx demonstrates excellent mechanical resilience to necessary electrode fabrication stresses, including high-shear agitation, ultrasonic processing and hot-pressing. In the anode catalyst layer, the quasi-ordered close packing of dh-IrOx nanospheres simultaneously maximizes electrochemically active surface area, suppresses particle migration and agglomeration, and establishes percolated electron highways and rapid mass transport channels. The architected anode delivers high PEMWE performance (e.g., 1 A cm-2 @1.60 V and 2 A cm-2 @1.75 V@80 °C), while demonstrating excellent operational durability with <1.5% voltage loss over 3000 h.

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.

Bias-Induced Ga-O-Ir Interface Breaks the Limits of Adsorption-Energy Scaling Relationships for High-Performing Proton Exchange Membrane Electrolyzers

Rationally manipulating the in situ formed catalytically active surface of catalysts remains a significant challenge for achieving highly efficient water electrolysis. Herein, we present a bias-induced activation strategy to modulate in situ Ga leaching and trigger the dynamic surface restructuring of lamellar Ir@Ga2O3 for the electrochemical oxygen evolution reaction. The in situ reconstructed Ga-O-Ir interface sustains high water oxidation rates at oxygen evolution reaction (OER) overpotentials. We found that OER at the Ga-O-Ir interface follows a bi-nuclear adsorbate evolution mechanism with unsaturated IrOx as the active sites, while GaOx atoms play an indirect role in promoting water dissociation to form OH* and transferring OH* to Ir sites. This breaks the scaling relationship of the adsorption energies between OH* and OOH*, significantly lowering the energy barrier of the rate-limiting step and greatly increasing reactivity. The Ir@Ga2O3 catalyst achieves lower overpotentials, a current density of 2 A cm-2 at 1.76 V, and stable operation up to 1 A cm-2 in scalable proton exchange membrane water electrolyzer (PEMWE) at 1.63 V, maintaining stable operation at 1 A cm-2 over 1000 hours with a degradation rate of 11.5 μV h-1. This work prompted us to jointly address substrate-catalyst interactions and catalyst reconstruction, an underexplored path, to improve activity and stability in Ir PEMWE anodes.

Effectiveness of strain and dopants on breaking the activity-stability trade-off of RuO2 acidic oxygen evolution electrocatalysts

Ruthenium dioxide electrocatalysts for acidic oxygen evolution reaction suffer from mediocre activity and rather instability induced by high ruthenium-oxygen covalency. Here, the tensile strained strontium and tantalum codoped ruthenium dioxide nanocatalysts are synthesized via a molten salt-assisted quenching strategy. The tensile strained spacially elongates the ruthenium-oxygen bond and reduces covalency, thereby inhibiting the lattice oxygen participation and structural decomposition. The synergistic electronic modulations among strontium-tantalum-ruthenium groups both optimize deprotonation on oxygen sites and intermediates absorption on ruthenium sites, lowering the reaction energy barrier. Those result in a well-balanced activity-stability profile, confirmed by comprehensive experimental and theoretical analyses. Our strained electrode demonstrates an overpotential of 166 mV at 10 mA cm-2 in 0.5 M H2SO4 and an order of magnitude higher S-number, indicating comparable stability compared to bare catalyst. It exhibits negligible degradation rates within the long-term operation of single cell and PEM electrolyzer. This study elucidates the effectiveness of tensile strain and strategic doping in enhancing the activity and stability of ruthenium-based catalysts for acidic oxygen evolution reactions.

Atomic-level Ru-Ir mixing in rutile-type (RuIr)O2 for efficient and durable oxygen evolution catalysis

The success of proton exchange membrane water electrolysis (PEMWE) depends on active and robust electrocatalysts to facilitate oxygen evolution reaction (OER). Heteroatom-doped-RuOx has emerged as a promising electrocatalysts because heteroatoms suppress lattice oxygen participation in the OER, thereby preventing the destabilization of surface Ru and catalyst degradation. However, identifying suitable heteroatoms and achieving their atomic-scale coupling with Ru atoms are nontrivial tasks. Herein, to steer the reaction pathway away from the involvement of lattice oxygen, we integrate OER-active Ir atoms into the RuO2 matrix, which maximizes the synergy between stable Ru and active Ir centers, by leveraging the changeable growth behavior of Ru/Ir atoms on lattice parameter-modulated templates. In PEMWE, the resulting (RuIr)O2/C electrocatalysts demonstrate notable current density of 4.96 A cm-2 and mass activity of 19.84 A mgRu+Ir-1 at 2.0 V. In situ spectroscopic analysis and computational calculations highlight the importance of the synergistic coexistence of Ru/Ir-dual-OER-active sites for mitigating Ru dissolution via the optimization of the binding energy with oxygen intermediates and stabilization of Ru sites.

NiIr Nanowire Assembles as an Efficient Electrocatalyst Towards Oxygen Evolution Reaction in Both Acid and Alkaline Media

Oxygen evolution reaction (OER) is the rate-limiting step in water electrolysis due to its sluggish kinetic, and it is challenging to develop an OER catalyst that could work efficiently in both acid and alkaline environment. Herein, NiIr nanowire assembles (NAs) with unique nanoflower morphology were prepared by a facile hydrothermal method. As a result, the NiIr NAs exhibited superior OER activity in both acid and alkaline media. Specifically, in 0.1 M HClO4, NiIr NAs presented a superior electrocatalytic performance with a low overpotential of merely 242 mV at 10 mA cm-2 and a Tafel slope of only 58.1 mV dec-1, surpassing that of commercial IrO2 and pure Ir NAs. And it achieved a significantly higher mass activity of 148.40 A/g at -1.5 V versus RHE. In 1.0 M KOH, NiIr NAs has an overpotential of 291 mV at 10 mA cm-2 and a Tafel slope of 42.1 mV dec-1. Such remarkable activity makes the NiIr NAs among the best of recently reported representative Ir-based OER electrocatalysts. Density functional theory (DFT) calculations confirmed alloying effect promotes surface bonding of NiIr with oxygen-containing reactants, resulting in excellent catalytic properties.

Multi-Component and Nanoporous Design toward RuO2-Based Electrocatalyst with Enhanced Performance for Acidic Water Splitting

Developing electrocatalysts with excellent activity and stability for water splitting in acidic media remains a formidable challenge due to the sluggish kinetics and severe dissolution. As a solution, a multi-component doped RuO2 prepared through a process of dealloying-annealing is presented. The resulting multi-doped RuO2 possesses a nanoporous structure, ensuring a high utilization efficiency of Ru. Furthermore, the dopants can regulate the electronic structure, causing electron aggregation around unsaturated Ru sites, which mitigates Ru dissolution and significantly enhances the catalytic stability/activity. The representative catalyst (FeCoNiCrTi-RuO2) shows an overpotential of 167 mV at 10 mA cm-2 for oxygen evolution reaction (OER) in 0.5 m H2SO4 solution with a Tafel slope of 53.1 mV dec-1, which is among the highest performance reported. Moreover, it remains stable for over 200 h at a current density of 10 mA cm-2. This work presents a promising approach for improving RuO2-based electrocatalysts, offering a crucial advancement for electrochemical water splitting.

Heterointerface MnO2/RuO2 with rich oxygen vacancies for enhanced oxygen evolution in acidic media

The design and synthesis of oxygen evolution reaction (OER) electrocatalysts that operate efficiently and stably under acidic conditions are important for the preparation of green hydrogen energy. The low intrinsic catalytic activity and poor acid resistance of commercial RuO2 limit its further development, and the construction of heterointerface structures is the most promising strategy to break through the intrinsic activity limitation of electrocatalysts. Herein, we synthesized spherical and oxygen vacancy-rich heterointerface MnO2/RuO2 using morphology control, which promoted the kinetics of the oxygen evolution reaction with the interaction between oxygen vacancies and the oxide heterointerface. MnO2/RuO2 was reported to be an acidic OER catalyst with excellent performance and stability, requiring only an ultra-low overpotential of 181 mV in 0.5 M H2SO4 to achieve a current density of 10 mA cm-2. The catalyst activity remained essentially unchanged in a 140 h stability test with an ultra-high mass activity (858.9 A g-1@ 1.5 V), which was far superior to commercial RuO2 and most previously reported noble metal-based acidic OER catalysts. The experimental results showed that the effect of more oxygen vacancies and the heterointerfaces of manganese ruthenium oxides broke the intrinsic activity limitation, provided more active sites for the OER, accelerated reaction kinetics, and improved the stability of the catalyst. The excellent performance of the catalyst suggests that MnO2/RuO2 provides a new idea for the design and study of heterointerfaces in metal oxide nanomaterials.

Controlled three-dimensional leaf-like NiCoO2@NiCo layered double hydroxide heterostructures for oxygen evolution electrocatalysts in rechargeable Zn-air batteries

Rechargeable zinc-air batteries (ZABs) have garnered attention as a viable choice for large-scale energy storage due to their advantageous characteristics, such as high energy density and cost-effectiveness. Strategies aimed at improving the kinetics of the oxygen evolution reaction (OER) through advanced electrocatalytic materials or structural designs can significantly enhance the efficiency and longevity of ZABs. In this study, we introduce a three-dimensional (3D) leaf-vein system heterojunction architecture. In this structure, NiCoO2 nanowire arrays form the central vein, surrounded by an outer leaf composed of NiCo layered double hydroxide (LDH) nanosheets. All these components are integrated onto a substrate made of Ni foam. Notably, when tested in an alkaline environment, the NiCoO2@NiCo LDH exhibited an overpotential of 272 mV at a current density of 10 mA cm-2, and extended durability evaluations over 12 h underscored its robustness at 99.76 %. The rechargeable ZABs achieved a peak power density of 149 mW cm-2. Furthermore, the NiCoO2@NiCo LDH demonstrated stability by maintaining high round-trip efficiencies throughout more than 680 cycles (equivalent to 340 h) under galvanostatic charge-discharge cycling at 5 mA cm-2. The leaf-vein system heterojunction significantly increased the active sites of the catalysts, facilitating charge transport, improving electronic conductivity, and enhancing overall stability.

Advanced membrane-based electrode engineering toward efficient and durable water electrolysis and cost-effective seawater electrolysis in membrane electrolyzers

Researchers have been seeking for the most technically-economical water electrolysis technology for entering the next-stage of industrial amplification for large-scale green hydrogen production. Various membrane-based electrolyzers have been developed to improve electric-efficiency, reduce the use of precious metals, enhance stability, and possibly realize direct seawater electrolysis. While electrode engineering is the key to approaching these goals by bridging the gap between catalysts design and electrolyzers development, nevertheless, as an emerging field, has not yet been systematically analyzed. Herein, this review is organized to comprehensively discuss the recent progresses of electrode engineering that have been made toward advanced membrane-based electrolyzers. For the commercialized or near-commercialized membrane electrolyzer technologies, the electrode material design principles are interpreted and the interface engineering that have been put forward to improve catalytic sites utilization and reduce precious metal loading is summarized. Given the pressing issues of electrolyzer cost reduction and efficiency improvement, the electrode structure engineering toward applying precious metal free electrocatalysts is highlighted and sufficient accessible sites within the thick catalyst layers with rational electrode architectures and effective ions/mass transport interfaces are enabled. In addition, this review also discusses the innovative ways as proposed to break the barriers of current membrane electrolyzers, including the adjustments of electrode reaction environment, and the feasible cell-voltage-breakdown strategies for durable direct seawater electrolysis. Hopefully, this review may provide insightful information of membrane-based electrode engineering and inspire the future development of advanced membrane electrolyzer technologies for cost-effective green hydrogen production.

Simultaneously Improved Activity and Stability for Acidic Water Oxidation of IrRu Oxides by a Dual Role of Tungsten Doping

Acidic oxygen evolution reaction (OER) remains a significant challenge due to the low activity and/or poor stability of the catalysts, even with state-of-the-art catalysts such as IrO2 and RuO2. Herein, we propose a strategy to enhance both the catalytic activity and stability of IrRu oxides for acidic OER by doping non-noble metal W. The W-doped IrRu3Ox (W-IrRu3Ox) undergoes a process of W leaching and reconstruction during the OER, leading to a more uniform distribution of elements, while the electronegative nature of W influences the electronic structures of Ir and Ru in W-IrRu3Ox. The dual role of W in promoting the formation of active site Ir5+ and inhibiting the concentration of soluble Ru>4+ ions results in a synergistic enhancement of both the activity and stability of acidic OER. Remarkably, W-IrRu3Ox exhibits outstanding catalytic activity for the OER in 0.5 M H2SO4, with a high stability of more than 500 h. This work presents a novel and feasible strategy for the development of efficient and stable catalysts for acid OER, shedding light on the design of advanced electrocatalysts for energy conversion and storage applications.

Breaking the Activity and Stability Bottlenecks of Electrocatalysts for Oxygen Evolution Reactions in Acids

Oxygen evolution reaction (OER) is a cornerstone reaction for a variety of electrochemical energy conversion and storage systems such as water splitting, CO2 /N2 reduction, reversible fuel cells, and metal-air batteries. However, OER catalysis in acids suffers from extra sluggish kinetics due to the additional step of water dissociation along with its multiple electron transfer processes. Furthermore, OER catalysts often suffer from poor stability in harsh acidic electrolytes due to the severe dissolution/corrosion processes. The development of active and stable OER catalysts in acids is highly demanded. Here,  the recent advances in OER electrocatalysis in acids are reviewed and the key strategies are summarized to overcome the bottlenecks of activity and stability for both noble-metal-based and noble metal-free catalysts, including i) morphology engineering, ii) composition engineering, and iii) defect engineering. Recent achievements in operando characterization and theoretical calculations are summarized which provide an unprecedented understanding of the OER mechanisms regarding active site identification, surface reconstruction, and degradation/dissolution pathways. Finally, views are offered on the current challenges and opportunities to break the activity-stability relationships for acidic OER in mechanism understanding, catalyst design, as well as standardized stability and activity evaluation for industrial applications such as proton exchange membrane water electrolyzers and beyond.

Nanotubular TiO x N y -Supported Ir Single Atoms and Clusters as Thin-Film Electrocatalysts for Oxygen Evolution in Acid Media

A versatile approach to the production of cluster- and single atom-based thin-film electrode composites is presented. The developed TiO _x N _y -Ir catalyst was prepared from sputtered Ti-Ir alloy constituted of 0.8 ± 0.2 at % Ir in α-Ti solid solution. The Ti-Ir solid solution on the Ti metal foil substrate was anodically oxidized to form amorphous TiO₂-Ir and later subjected to heat treatment in air and in ammonia to prepare the final catalyst. Detailed morphological, structural, compositional, and electrochemical characterization revealed a nanoporous film with Ir single atoms and clusters that are present throughout the entire film thickness and concentrated at the Ti/TiO _x N _y -Ir interface as a result of the anodic oxidation mechanism. The developed TiO _x N _y -Ir catalyst exhibits very high oxygen evolution reaction activity in 0.1 M HClO₄, reaching 1460 A g^-1 _Ir at 1.6 V vs reference hydrogen electrode. The new preparation concept of single atom- and cluster-based thin-film catalysts has wide potential applications in electrocatalysis and beyond. In the present paper, a detailed description of the new and unique method and a high-performance thin film catalyst are provided along with directions for the future development of high-performance cluster and single-atom catalysts prepared from solid solutions.

High-Valence-Manganese Driven Strong Anchoring of Iridium Species for Robust Acidic Water Oxidation

Designing an efficient and durable electrocatalyst for the sluggish anodic oxygen evolution reaction (OER) has been the primary goal of using proton exchange membrane electrolyzer owing to the highly acidic and oxidative environment at the anode. In this work, it is reported that high-valence manganese drives the strong anchoring of the Ir species on the manganese dioxide (MnO2 ) matrix via the formation of an Mn-O-Ir coordination structure through a hydrothermal-redox reaction. The iridium (Ir)-atom-array array is firmly anchored on the Mn-O-Ir coordination structure, endowing the catalyst with excellent OER activity and stability in an acidic environment. Ir-MnO2 (160)-CC shows an ultralow overpotential of 181 mV at j = 10 mA cm-2 and maintains long-term stability of 180 h in acidic media with negligible decay, superior to most reported electrocatalysts. In contrast, when reacting with low-valence MnO2 , Ir species tend to aggregate into IrOx nanoparticles, leading to poor OER stability. Density functional theory (DFT) calculations further reveal that the formation of the Mn-O-Ir coordination structure can optimize the adsorption strength of *OOH intermediates, thus boosting the acidic OER activity and stability.

Oxygen Evolution Electrocatalysts for the Proton Exchange Membrane Electrolyzer: Challenges on Stability

Hydrogen generated by proton exchange membrane (PEM) electrolyzer holds a promising potential to complement the traditional energy structure and achieve the global target of carbon neutrality for its efficient, clean, and sustainable nature. The acidic oxygen evolution reaction (OER), owing to its sluggish kinetic process, remains a bottleneck that dominates the efficiency of overall water splitting. Over the past few decades, tremendous efforts have been devoted to exploring OER activity, whereas most show unsatisfying stability to meet the demand for industrial application of PEM electrolyzer. In this review, systematic considerations of the origin and strategies based on OER stability challenges are focused on. Intrinsic deactivation of the material and the extrinsic balance of plant-induced destabilization are summarized. Accordingly, rational strategies for catalyst design including doping and leaching, support effect, coordination effect, strain engineering, phase and facet engineering are discussed for their contribution to the promoted OER stability. Moreover, advanced in situ/operando characterization techniques are put forward to shed light on the OER pathways as well as the structural evolution of the OER catalyst, giving insight into the deactivation mechanisms. Finally, outlooks toward future efforts on the development of long-term and practical electrocatalysts for the PEM electrolyzer are provided.

Highly clean and efficient iron phosphates modified by Ru nanocrystals for water oxidation

Optimizing the architecture of non-polluting, highly efficient, robust, and cost-effective electrocatalysts for the oxygen evolution reaction (OER) is extremely crucial for accelerating the application of water splitting. Herein, a highly green and active OER electrocatalyst composed of Ru nanocrystal modified iron-rich phosphates is successfully developed via a hydrothermal and post-annealing approach. The eco-friendly phosphorus source of lecithin is employed to fabricate transition metal phosphates for the first time, which avoids the use of toxic and dangerous phosphorus sources. Meanwhile, it is found that Ru nanocrystals could form heterostructures with iron phosphates and induce conversion to iron-rich phosphates, which would greatly enhance the conductivity of the substrate and elevate the catalytic activity. As a result, overpotentials of only 250 mV and 290 mV are required to deliver 10 and 100 mA cm^-2 using this typical electrocatalyst. Also, the j-t curve shows no distinct variations in current over 45 h at a constant overpotential of 334 mV, indicating the outstanding activity and durability of the catalyst. Furthermore, nickel/cobalt-rich phosphates and phosphides were also acquired using similar experimental procedures, manifesting the wide applicability of Ru actuation. Hence, this work offers a convenient and scalable method for designing highly efficient, green, clean, and cost-effective electrocatalysts for water splitting.

Catalytic Kinetics Regulation for Enhanced Electrochemical Nitrogen Oxidation by Ru-Nanoclusters-Coupled Mn3 O4 Catalysts Decorated with Atomically Dispersed Ru Atoms

Electrochemical N₂ oxidation reaction (NOR), using water and N₂ in the atmosphere, represents a sustainable approach for nitric production to replace the conventional industrial synthesis with high energy consumption and greenhouse gas emission. Meanwhile, owing to chemical inertness of N₂ and sluggish kinetics for 10-electron transfer, emerging electrocatalysts remain largely underexplored. Herein, Ru-nanoclusters-coupled Mn₃ O₄ catalysts decorated with atomically dispersed Ru atoms (Ru-Mn₃ O₄ ) are designed and explored as an advanced electrocatalyst for ambient N₂ oxidation, with an excellent Faraday efficiency (28.87%) and a remarkable NO₃ ^- yield (35.34 µg h^-1 mg^-1 _cat. ), respectively. Experiments and density functional theory calculations reveal that the outstanding activity is ascribed to the coexistence of Ru clusters and single-atom Ru. The synergistic effect between the Ru clusters and Mn₃ O₄ can effectively activate the chemically inert N₂ , lowering the kinetic barrier for the vital breakage of N≡N. The intensive *OH supply and enhanced conductivity are used to regulate the catalytic kinetics for optimized performance. This work provides brand-new ideas for the rational design of electrocatalysts in complicated electrocatalytic reactions with multiple dynamics-different steps.