Key Takeaways & Executive Findings
- •• A rapid laser irradiation method enables the synthesis of sub-10 nm FeCoNiMnCr high-entropy alloy nanoparticles on carbon nanotube paper, achieving homogeneous elemental mixing and phase-pure FCC structure. • The ultrafast heating and quenching processes suppress Ostwald ripening, leading to ultrafine nanoparticles with enhanced catalytic performance. • The synthesized catalyst exhibits exceptional OER activity with a low overpotential of 255 mV at 10 mA·cm−2 and remarkable stability over 100 hours in alkaline media. • This work provides a scalable and efficient strategy for the preparation of high-entropy alloy nanoparticle catalysts, advancing cost-effective renewable energy conversion.
Abstract
The development of efficient and robust oxygen non-precious catalysts for the oxygen evolution reaction (OER) remains a critical scientific hurdle in realizing cost-effective renewable energy conversion systems. Herein, we present a rapid laser irradiation synthesis strategy for the successful fabrication of sub-10 nm FeCoNiMnCr high-entropy alloy nanoparticles (HEA-NPs) on multi-wall carbon nanotube (MWCNT) paper, serving as highly efficient OER electrocatalysts. The synthesis of high-entropy alloy nanoparticles with precise control was accomplished through systematic optimization of laser processing parameters. Structural characterization via X-ray diffraction, high-resolution transmission electron microscopy, and high-angle annular dark-field scanning transmission electron microscopy collectively verified the formation of a phase-pure face-centered cubic crystal structure with homogeneous elemental mixing at the atomic scale. Furthermore, COMSOL Multiphysics simulations confirm that this rapid and discontinuous laser irradiation approach enables the precursor material to undergo ultrafast heating and quenching processes, effectively suppressing Ostwald ripening phenomena, which is conducive to the formation of ultrafine (sub-10 nm) high-entropy alloy nanoparticles. The synthesized HEA-NPs catalyst demonstrates exceptional oxygen evolution activity in alkaline electrolyte (1 M KOH), achieving a current density of 10 mA·cm−2 at a low overpotential of 255 mV while maintaining remarkable stability with negligible activity decay during prolonged operation (>100 h), representing state-of-the-art performance among non-precious metal catalysts. This study provides perspectives on the rapid preparation and performance regulation of HEA-NPs catalysts.
1. Introduction
The ongoing global energy transition necessitates the advancement of clean hydrogen production technologies as a pivotal pathway toward carbon neutrality, driven by the urgent need to decarbonize industrial and transportation sectors [1–2]. Renewable energy-powered electrochemical water splitting, with its zero-carbon emission characteristics, is regarded as a highly viable pathway for sustainable hydrogen generation [3–5]. However, the large-scale commercialization of this technology faces a fundamental challenge: the inherently slow kinetics of water splitting, particularly the oxygen evolution reaction (OER), involving a four-electron transfer process, results in a thermodynamic energy barrier of 1.23 V, often requiring an additional overpotential of 350–500 mV in practical operation [6–8]. More critically, the current reliance on Ir/Ru-based noble metal catalysts faces fundamental bottlenecks of resource scarcity and prohibitive costs (accounting for up to 35% of total system expenses) [9–11]. Consequently, there is an urgent need to design and synthesize high-performance oxygen evolution reaction (OER) electrocatalysts based on earth-abundant transition metals, given their critical importance in sustainable energy applications.
In recent years, high-entropy alloys (HEAs) have risen to prominence in electrocatalytic applications owing to their exceptional capability for electronic structure modulation through d-band center engineering and the so-called “cocktail effect” arising from multi-component interactions [12–13]. The distinctive characteristic of HEAs lies in their high configurational entropy (ΔSmix ≥ 1.5R, R represents the gas constant), which not only stabilizes single-phase solid solutions but also generates a high density of catalytically active sites [14–16]. Arc melting [17], aerosol spray pyrolysis [18], solvothermal method [19], and carbothermal impact method [20] are the traditional methods used for the synthesis of HEAs. Nevertheless, the synthesis of high-entropy alloy nanoparticles (HEA-NPs) via existing approaches often results in inconsistent elemental distribution among particles, along with significant heterogeneity in size and morphology. Additionally, many of these techniques involve intricate and labor-intensive processes, which are not only time-consuming but also difficult to precisely control.
Herein, we developed a rapid laser-assisted synthesis approach for fabricating compositionally homogeneous FeCoNiMnCr high-entropy alloy nanoparticles (
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Jiuyang Xia, Jianghong Zhang, Mingzhen Xiu, Bowei Zhang, Zehong Zhou, Yu Lu, Yizhong Huang, Junsheng Wu (2025). Ultrafast laser synthesis of sub-10 nm FeCoNiMnCr high-entropy alloy nanoparticles for enhanced oxygen evolution catalysis. Int. Journal of Minerals, Metallurgy and Materials (矿物冶金与材料学报). https://doi.org/10.1007/s12613-025-3276-6
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Frequently Asked Questions
What is the significance of using high-entropy alloy nanoparticles for oxygen evolution reaction?
High-entropy alloy nanoparticles offer exceptional catalytic performance due to their high configurational entropy, which stabilizes single-phase solid solutions and creates a high density of active sites. This leads to enhanced OER activity and stability compared to traditional catalysts.
How does the laser synthesis method work for producing sub-10 nm nanoparticles?
The laser irradiation method induces ultrafast heating and quenching of the precursor material, which suppresses Ostwald ripening and enables the formation of ultrafine nanoparticles with homogeneous elemental distribution.
What are the key performance metrics of the synthesized catalyst?
The FeCoNiMnCr HEA-NPs catalyst achieves a current density of 10 mA·cm−2 at a low overpotential of 255 mV in 1 M KOH, with remarkable stability over 100 hours of operation.
Why is the development of non-precious metal catalysts important?
Non-precious metal catalysts are crucial for reducing the cost of renewable energy conversion systems, as noble metals like Ir and Ru are scarce and expensive, accounting for up to 35% of total system expenses.
What are the potential applications of this research?
This research provides a scalable and efficient method for preparing high-entropy alloy nanoparticle catalysts, which can be applied in electrochemical water splitting for clean hydrogen production, contributing to sustainable energy solutions.
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