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Corrosion Resistance and Catalytic Activity toward the Oxygen Reduction Reaction of CoCrFexNi (0 < x < 0.7) Thin Films
Linköping University, Department of Physics, Chemistry and Biology, Nanostructured Materials. Linköping University, Faculty of Science & Engineering. RISE, Sweden.
Linköping University, Department of Physics, Chemistry and Biology, Thin Film Physics. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0001-9630-7071
Linköping University, Department of Physics, Chemistry and Biology, Nanostructured Materials. Linköping University, Faculty of Science & Engineering. Linköping University, Department of Physics, Chemistry and Biology, Plasma and Coating Physics.ORCID iD: 0000-0002-6602-7981
Linköping University, Department of Physics, Chemistry and Biology, Thin Film Physics. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0002-3059-7392
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2022 (English)In: ACS Applied Energy Materials, E-ISSN 2574-0962, Vol. 5, no 9, p. 10838-10848Article in journal (Refereed) Published
Abstract [en]

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 &lt;= x &lt;= 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 &gt;= 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.

Place, publisher, year, edition, pages
American Chemical Society (ACS), 2022. Vol. 5, no 9, p. 10838-10848
Keywords [en]
magnetron sputtering; multicomponent thin film; corrosion; ORR; water recombination; electrocatalysis
National Category
Other Chemistry Topics
Identifiers
URN: urn:nbn:se:liu:diva-188445DOI: 10.1021/acsaem.2c01499ISI: 000848746100001OAI: oai:DiVA.org:liu-188445DiVA, id: diva2:1695786
Note

Funding Agencies|Swedish Agency for Innovation Systems (VINNOVA) [2016-05156, 2019-04881]; Swedish Government Strategic Research Area in Materials Science on Functional Materials at the Linkoping University [2009 00971]; Swedish Research Council [2021-03826]

Available from: 2022-09-14 Created: 2022-09-14 Last updated: 2024-10-01Bibliographically approved
In thesis
1. Cantor-Alloy-Based Multicomponent Nitride Thin Films
Open this publication in new window or tab >>Cantor-Alloy-Based Multicomponent Nitride Thin Films
2023 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In this Thesis, I have investigated multicomponent alloy based thin films synthesized by magnetron sputtering. The studies in the thesis are centered around the phase diagram of the CrFeCoNi nitrogen containing system. Theoretical and experimental methods were employed to understand the phase formation in this system which is related to the archetypical Cantor alloy (CrMnFeCoNi). CrFeCoNi thin films of approximately equimolar composition crystallize with fcc structure when grown at room temperature. This structure, however, is not retained when nitrogen (x) is added into the lattice. Density functional theory calculations together with the experimental investigation on the (CrFeCoNi)Nx system revealed the stabilization of the metallic fcc when x ≤ 0.22 and the stabilization of the NaCl B1 structure when x > 0.33, consistent with the theoretical prediction. In contrast, films with intermediate amounts of nitrogen (x = 0.22) grown at higher temperatures show segregation into multiple phases of CrN, Fe-Ni-rich and Co. These results offer an explanation for the requirement of kinetically limited growth conditions at low temperature for obtaining single-phase CrFeCoNi Cantor-like nitrogen-containing thin films. The importance of the phase diagram is realized when attempting to grow much more complex structures for application-oriented research such as irradiation resistance, corrosion resistance as well as epitaxial films for a fundamental understanding of the material system. The phase diagram of the CrFeCoNi system indicated that higher stability of the single-phase solid solution Cantor nitride lay in a limited temperature range of 200 to 300 °C. In order to compensate for the higher deposition temperature required to grow epitaxial films magnetic field assisted dc magnetron sputtering was used. This technique allows for the control of the flux of Ar ions bombarding the substrate during growth thereby providing the growing film with kinetic energy as opposed to thermal. The results from the study indicated that the quality of epitaxy can be improved by increasing low ion energy, high ion-flux bombardment. The thesis in whole, gives a fundamental understanding of the nitride cantor alloy material system in terms of crystal structure, mechanical and electrical properties.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2023. p. 46
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 2287
Keywords
Thin films, Multicomponent alloys, Magnetron sputtering
National Category
Condensed Matter Physics
Identifiers
urn:nbn:se:liu:diva-191824 (URN)10.3384/9789180750424 (DOI)9789180750417 (ISBN)9789180750424 (ISBN)
Public defence
2023-03-15, NOBEL-BL32, B Building, Campus Valla, Linköping, 09:15 (English)
Opponent
Supervisors
Note

Funding agencies: VINNOVA Competence Centre FunMat-II (grant no. 2016-05156), the Swedish Government Strategic Research Area in Materials Science on Functional Materials at Linköping University (Faculty Grant SFO-Mat-LiU No. 2009 00971), and the Centre in Nanoscience and technology at LiTH, (CeNano)

Available from: 2023-02-17 Created: 2023-02-17 Last updated: 2023-02-17Bibliographically approved
2. Tailoring multicomponent thin films for combined corrosion resistance and oxygen electrocatalysis
Open this publication in new window or tab >>Tailoring multicomponent thin films for combined corrosion resistance and oxygen electrocatalysis
2024 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Catalytic water recombination and electrolysis play an important role in the transition towards green, renewable, fossil-free energy production. The processes are kinetically limited by the oxygen reactions, i.e. Oxygen Reduction Reaction (ORR) and Oxygen Evolution Reaction (OER), thus these reactions have higher demand for electrocatalysts than the hydrogen reactions. There is a particular focus on finding abundant and cheap alternatives to noble metal oxygen reaction catalysts used today. Alternatives such as Co, Ni, Fe and Mn oxides, are promising candidates and in some cases found to be bifunctional oxygen catalysts, i.e. that they are active towards both reactions. In this thesis, these catalytically active elements have been alloyed together in multicomponent, high entropy thin films deposited by magnetron sputtering. 

Anodization profiles have been designed to activate the thin films by tuning the surface oxidation states. This considerably enhanced the catalytic activity towards both ORR and OER. For pure Co films, the electrochemical modification resulted in the formation of Co3O4 platelets with the two Co cations as active sites. In the CoCrFeNi films, an enrichment of the surface in Co and Ni cations was observed after anodization. In addition, the presence of Fe and its synergy with the active sites was identified as key to the catalytic activity.   

Another critical aspect was the film structure. Here the substrate bias was varied which affected the ion bombardment during the deposition. This changed the typical columnar structure of the films towards denser and more faceted films with larger grains. Both the columnar and denser structure were found catalytically active, in particular towards OER. The denser films had better long-term stability towards OER compared to the columnar films.   To understand in depth the catalytic mechanism for the CoCrFeNi and MnCrFeNi films, the ORR pathway was also investigated. It was first observed that replacing Co with Mn reduced the overpotentials for both ORR and OER. The as-deposited films follow a (2+1) electrons pathway whereas the anodized films shifted towards either 4 or 2 electrons pathway. This was also correlated to the active sites and film structure. 

Furthermore, the films synthesized in this thesis have also a high corrosion resistance in alkaline and neutral chloride containing environments. The films presented a passive behavior due to the formation of a protective oxide layer. Once again, film composition and film structure, in particular grain size affected the corrosion performance. The presence of defects due to lattice distortion of CoCrFeNi significantly improved the corrosion resistance in NaCl. The smaller grain size of the films led to a higher corrosion resistance in KOH. Additions of Mo to CoCrFeNi significantly improve the corrosion resistance in acidic environments at elevated temperature. This was attributed to the suppression of secondary phases and presence of Mo in the passive films.  

In summary, this thesis focuses on tuning thin film composition, structure, and post-deposition oxidation to improve both the catalytic activity towards oxygen reactions and the corrosion resistance in environments relevant for cata-lytic water recombination and electrolysis. The focus on abundant and cheap elements for material synthesis aims to contribute to the development of non-noble metal oxygen electrocatalysts for potential use in future green energy technologies.   

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2024. p. 55
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 2410
Keywords
Multicomponent alloys, Thin films, Magnetron sputtering, Oxygen electrocatalysis, PGM free catalysts, Anodization, Corrosion.
National Category
Inorganic Chemistry
Identifiers
urn:nbn:se:liu:diva-208074 (URN)10.3384/9789180757904 (DOI)9789180757898 (ISBN)9789180757904 (ISBN)
Public defence
2024-10-24, A2, A-building, Campus Valla, Linköping, 09:15 (English)
Opponent
Supervisors
Note

Funding: This work is supported by the Vinnova Competence Centre FunMat-II (grant no 2016-05156 and 2022-03071), the Vinnova grants no 2018-04291 and no 2019-04881, the Swedish Energy Agency grant no 2020-024828 and 52740-1, and the Swedish Government Strategic Research Area in Materials Science on Ad-vanced Functional Materials at Linköping University (Faculty Grant SFO-Mat-LiU No. 2009 00971). 

Available from: 2024-10-01 Created: 2024-10-01 Last updated: 2024-10-02Bibliographically approved

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Linder, ClaraGangaprasad Rao, SmitaBoyd, RobertLe Febvrier, ArnaudEklund, PerBjörk, Emma

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