The
oxygen evolution reaction represents a key source of inefficiency
for green hydrogen production. In general, persistent bubbles that
grow on the surfaces of an electrode obstruct a portion of the electrochemically
active surface area, resulting in a decreased overall efficiency.
Microscale features on the surfaces of electrocatalysts can, however,
aid in the removal of these adherent bubbles. Gas production and conversion
efficiencies have been shown to improve when incorporating linear,
ridge-like microscale features onto electrodes. These factors improve
with an increase in the separation between these ridges as demonstrated
for features with separations up to 200 μm, but the full extent
of this trend is not known. In this study, a series of linear, ridge-like
features were prepared to seek a separation between these features
that yields an optimal performance. The ridge-like features were prepared
from nickel (Ni) using microscope project lithography techniques in
combination with Ni electrodeposition, which was demonstrated to be
a versatile technique for rapidly prototyping these features. At an
industrially relevant potential of 1.8 V [vs mercury/mercury oxide
(Hg/HgO)] in an alkaline electrolyte, the performance of arrays of
the ridge-like features was observed to increase up to a critical
separation of ∼300 μm, beyond which the performance decreased
and approached that of planar Ni electrocatalysts. At this identified
critical separation of features, the current response under chronoamperometry
conditions was nearly triple that obtained for the planar Ni electrocatalysts.
Observations of growth, coalescence, and detachment of gas bubbles
on the microscale ridge-like features achieved using high-speed imaging
suggest a possible cause for the improved performance at the identified
optimal spacing of the arrays of linear features.