Catalysts and electmcatalysts are crucial for energy production and storage. To develop cost-efficient systems taking advantage of functionalized surfaces, the catalysts can be synthesized as nanomaterials or thin films. In this work, cobalt thin films were deposited on low-alloyed steel using magnetron sputtering. The films are uniform with a smooth surface and a thickness of similar to 400 nm. The films were electrochemically oxidized via anodization to a mix of cobalt oxides, one of them being Co3O4, at room temperature in an alkaline solution. The electrocatalytic performances of the anodized films were evaluated in 1 M KOH electrolyte saturated with oxygen. Cathodic currents in -0.5 mA/cm(2) range, corresponding to oxygen reduction reaction (ORR) activity, were measured with cyclic voltammetry. The catalytic activity of the films was evaluated as a function of time. The anodized Co coating exhibited three times higher activity than the steel substrate. The kinetics for the ORR were evaluated through Tafel plots and a slope of 226 mV/decade was found. Post-ORR characterization of the films revealed hexagonal plate-like oxide particles on the surface. After 50 cyclic voltammograms, the film was further oxidized, indicating that the ORR activity also affects the overall surface state of the film. This study demonstrates that thin films, after electrochemical modification, can be electrocatalysts for the oxygen reduction reaction and potentially used for applications in energy production and storage.

Corrosion resistance and catalytic activity toward the oxygen reduction reaction (ORR) in an alkaline environment are two key properties for water recombination applications. In this work, CoCrFexNi (0 <= x <= 0.7) thin films were deposited by magnetron sputtering on polished steel substrates. The native passive layer was 2-4 nm thick and coherent to the columnar grains determined by transmission electron microscopy. The effect of Fe on the corrosion properties in 0.1 M NaCl and 1 M KOH and the catalytic activity of the films toward ORR were investigated. Electrochemical impedance spectroscopy and potentiodynamic polarization measurements indicate that CoCrFe0.7Ni and CoCrFe0.3Ni have the highest corrosion resistance of the studied films in NaCl and KOH, respectively. The high corrosion resistance of the CoCrFe0.7Ni film in NaCl was attributed to the smaller overall grain size, which leads to a more homogeneous film with a stronger passive layer. For CoCrFe0.3Ni in KOH, it was attributed to a lower Fe dissolution into the electrolyte and the build-up of a thick and protective hydroxide layer. Scanning Kelvin probe force microscopy showed no potential differences globally in any of the films, but locally, a potential gradient between the top of the columns and grain boundaries was observed. Corrosion of the films was likely initiated at the top of the columns where the potential was lowest. It was concluded that Fe is essential for the electrochemical activation of the surfaces and the catalytic activity toward ORR in an alkaline medium. The highest catalytic activity was recorded for high Fe-content films (x >= 0.5) and was attributed to the formation of platelet-like oxide particles on the film surface upon anodization. The study showed that the combination of corrosion resistance and catalytic activity toward ORR is possible for CoCrFexNi, making this material system a suitable candidate for water recombination in an alkaline environment.

(CoCrFeNi)_1−xMo_x thin films with various Mo content (0–10 at.%) were grown by magnetron sputtering on a stainless steel substrate. The films with 0–2 at.% presented two crystal structures: one FCC phase and one sigma phase, while films with higher Mo content only had the FCC structure. All films have a (111) texture and follow the topography of the substrate. The corrosion resistance of the films was evaluated in 0.05 M H₂SO₄ at room temperature and at 80 °C. It was observed that the corrosion current densities considerably decreased for Mo > 2 at%, and that the current densities were higher at the elevated temperature. Scanning Kelvin Probe Force Microscopy showed a large potential difference between the main FCC phase and sigma phase for the Mo0–2 films. This would suggest that preferential dissolution of the FCC phase occurs over the sigma and reduces the corrosion resistance. Such preferential dissolution does not occur for the higher Mo content films with only the FCC phase. The high corrosion resistance was also attributed to the inhibition of Fe and Cr dissolution by Mo and the stabilisation of the Cr enriched oxide by incorporating Mo oxides into the passive film, identified by X-ray photoelectron spectroscopy. The low corrosion current densities (below 1 µA/cm²) make these thin films possible candidates for protective coatings of bipolar plates in PEM fuel cells.