| Abstract Scope |
Electrochemical water splitting is a promising route for sustainable green hydrogen production, but large-scale deployment demands electrocatalysts that can perform efficiently at industry-relevant high current densities. Here, we present NiFe and NiMn oxy-hydroxide electrocatalysts for the oxygen and hydrogen evolution reactions (OER and HER), respectively, synthesized via acoustic cavitation-assisted electrodeposition. This approach promotes nanoscale structuring, partial amorphization, and oxygen vacancy formation, enhancing catalytic activity and durability. The catalysts exhibit low overpotentials of 285 mV (OER) and 189 mV (HER) at 1000 mA/cm². A full-cell configuration delivered 1 A/cm² at just 1.71 V and showed stable operation for 24 hours. Commercial feasibility was demonstrated in a 2.5 × 2.5 cm² anion-exchange membrane (AEM) stack, operating up to 1.2 A/cm². The potential required to reach industry-relevant high current densities of 500 and 1000 mA/cm² was 2.1 V and 2.5 V, respectively. Long-term tests confirmed excellent durability over 100 hours of continuous operation. |