Effect of Surface Engineering of Nickel Foam on Hydrogen Evolution Reaction: A Comprehensive Study for High Throughput

Interfacial engineering plays a key role in enhancing the performance of electrocatalysts for Hydrogen evolution reaction (HER). Surface modification of porous transport layer (PTL) enhances the active catalytic sites, improves membrane electrode interfacial contact, and facilitates efficient mass transport during water electrolysis. In this study, we report a simple, cost and time effective mechanical bilateral polishing technique to engineer the surface of nickel foam (NF) for efficient HER. The structural and surface analysis, using X‐ray diffraction (XRD), field emission scanning electron microscopy (FESEM), X‐ray photoelectron spectroscopy (XPS), contact angle measurement, and 3D X‐ray CT, confirms the effective removal of unwanted dendritic microstructures, enhanced wettability, and a more uniform catalyst coating, leading to increased active catalytic sites. Contact pressure analysis shows improved interfacial contact between the engineered NF, membrane and monopolar/bipolar plates. The relative electrochemical half‐cell measurements show that the Pt/C coated engineered NF delivers a significantly higher current density of −552.55 mA cm ⁻² compared to −357.85 mA cm ⁻² for the Pt/C coated bare NF at lower overpotentials. In a 13 cm ² AEM electrolyzer cell, the Pt/C@Eng // RuO ₂ @Eng configuration demonstrates a superior current density of 283.9 mA cm ⁻² compared to 156.63 mA cm ⁻² for the bare Pt/C // RuO ₂ configuration. A stability test of over 155 h shows robust durability. This work highlights the effectiveness of a simple surface engineering approach for NF in improving the HER.