Multifunctional AlCoCrFeNi High-Entropy Alloy Electrodes Fabricated by Cold Spray for Next-Generation Hydrogen Production

Durable and cost-effective electrode materials remain a key challenge in electrochemical hydrogen (H₂) production, where platinum-group catalysts are widely used but are expensive and vulnerable to degradation in harsh industrial environments. This work investigates the high-entropy alloy AlCoCrFeNi as a multifunctional alternative material for next-generation H₂ production systems. The entropy-stabilized structure of AlCoCrFeNi provides exceptional thermal stability, corrosion resistance, and tunable electrocatalytic activity, enabling its potential use as a replacement for conventional platinum-based electrodes. The alloy will be deposited using high-pressure cold spray (HPCS) to fabricate robust electrode and membrane components suitable for high-temperature operation. This study examines the relationships between HEA microstructure, catalytic activity, and durability during hydrogen generation. By integrating advanced alloy design with scalable manufacturing, the work aims to demonstrate a cost-effective pathway to reduce reliance on precious metals while improving efficiency and lifetime of hydrogen production systems in industrial environments.