Alkaline water electrolysis has the
potential to become an important
method for producing green hydrogen and achieving net-zero carbon
emissions. Consequently, the development of catalysts with higher
catalytic values for the hydrogen evolution reaction (HER) is essential
for advancing the water-splitting technology. This study introduces
a facile deposition strategy using aerosol-assisted chemical vapor
deposition to fabricate a bimetallic RuCo alloy on nickel foam (NF),
which serves as a Pt-free, high-performance HER catalyst under alkaline
conditions. The synergy between Co and Ru, along with the structural
advantages of RuCo@NF, significantly enhances the electrocatalytic
performance. The optimized RuCo@NF catalyst exhibited HER activity,
achieving current densities of 10 and 100 mA cm–2 at low overpotentials of 17 and 100 mV, respectively. Moreover,
it had a minimal Tafel slope of 42 mV dec–1 and
demonstrated stability over 24 h, surpassing that of the benchmark
Pt/C catalyst when measured in 1.0 M KOH. Furthermore, density functional
theory analysis validated the experimental results, revealing a lower
Gibbs free energy value for the RuCo alloy (−0.35 eV) compared
to that of metallic Ru (−0.50 eV) and Co (−0.57 eV)
in the HER process. This study presents a convenient pathway for the
development of a highly active and robust bimetallic thin-film electrocatalyst,
demonstrating its potential for hydrogen production in fuel cells.