Scalable Conformal MoSx Catalyst for Efficient Hydrogen Evolution at Industrial-Level Current Density in Alkaline Electrolyzers

The development of simple and scalable fabrication strategies for cost-effective electrodes is crucial to advance water splitting in alkaline water electrolyzers (AWEs). Here, we present a coating-annealing method to conformally coat a MoSx catalyst layer onto a porous Ni foam (NF) substrate. By controlling the annealing process, the composition of the MoSx layer could be tuned from MoS2 to MoS3 and its catalytic performance for hydrogen evolution reaction (HER) in alkaline media was optimized. The MoS3@NF synthesized by this method achieved industrially relevant HER current densities of 200 mA/cm2 at a low overpotential of 246 mV, maintaining stable operation for over 240 h. The MoS3@NF cathode, combined with a stainless steel anode, enabled an alkaline water electrolyzer (AWE) cell to operate steadily at 1.96 V and 1 A/cm2 for 1000 h. This performance surpasses that of most of the previously reported water electrolyzers employing MoSx-based cathodes. Our work demonstrates the potential of MoS3 (with its abundant edge-sulfur atoms serving as active sites) as a high-performance cathode material for industrial AWEs.