High-entropy alloy (HEA) as electrocatalyst for hydrogen production

Priority research theme: Hydrogen as an Alternate Fuel Source
Awarded: Winter 2026

Overview

Hydrogen (H₂) is a key energy carrier for storage, transport, and conversion, but most of today’s production relies on natural gas, resulting in significant carbon emissions. Water electrolysis—splitting water into hydrogen and oxygen using electricity—is a cleaner alternative, but it remains energy-intensive. Much of this inefficiency comes from energy losses at the electrodes, where slow reaction kinetics require higher operating voltages.

Improving electrode performance depends on effective electrocatalysts. Current systems often rely on platinum-group metals (PGMs), which offer excellent performance but are expensive and scarce—limiting large-scale adoption. Developing cost-effective alternatives that maintain high efficiency is therefore critical to advancing a hydrogen-based energy system.

This project explores the use of high-entropy alloys (HEAs) as next-generation electrocatalysts. Unlike single-metal systems, HEAs combine multiple elements in near-equal proportions, creating unique electronic structures and strong chemical stability. The research will focus on an equiatomic AlCoCrFeNi alloy, designed to reduce the energy required for water splitting.

The materials will be produced using cold spray additive manufacturing (CSAM), a solid-state process that enables layered deposition while preserving material properties. The performance of these HEA-based electrodes will be compared to conventional platinum-based systems, with testing under both acidic and alkaline conditions to evaluate efficiency, stability, and durability.

Expected outcomes include the development of a lower-cost, high-performance electrocatalyst and a better understanding of how material composition and manufacturing methods influence performance. Ultimately, this work supports more efficient and scalable hydrogen production, contributing to the transition toward low-carbon energy systems.