Ion Beam Sputtering Deposition to Prepare Pt/ZrO2 Active Layer for Hydrogen Evolution and Oxidation Reaction

The development of efficient and cost-effective bifunctional electrocatalysts is vital for advancing hydrogen-based energy technologies. In this study, we present a robust method for fabricating Pt@ZrO2 electrodes tailored for both the hydrogen evolution reaction and hydrogen oxidation reaction. Using ion beam sputtering deposition, we rapidly and economically deposited a mixed Pt-Zr layer onto FTO substrates. This approach enabled the formation of Pt@ZrO2, a high-performance ceramic-based electrocatalyst exhibiting excellent activity and durability under alkaline conditions. Compared to our previously studied Pd@ZrO2 thin films, Pt@ZrO2 shows markedly lower charge transfer resistance and improved electrocatalytic activity, as evidenced by electrochemical impedance spectroscopy measurements. The enhanced performance is attributed to the strong synergistic interaction between Pt and ZrO2, which, further enhanced by the adopted deposition technique, stabilizes Pt in a partially oxidized state, thereby promoting the Volmer step and improving charge transfer kinetics. Cyclic voltammetry further confirms the electrochemical stability of Pt@ZrO2 under prolonged operational stress. Notably, this deposition technique significantly reduces noble metal loading without compromising catalytic performance, offering a scalable and cost-efficient route for electrode fabrication. Overall, Pt@ZrO2 emerges as a superior alternative to Pd@ZrO2 and a promising candidate for next-generation hydrogen energy applications, underlining the effectiveness of the proposed preparation method.