Periodic Reporting for period 2 - NICKEFFECT (Ni-BASED FERROMAGNETIC COATINGS WITH ENHANCED EFFICIENCY TO REPLACE Pt IN ENERGY & DIGITAL STORAGE APPLICATIONS)
Période du rapport: 2023-12-01 au 2025-05-31
Platinum group metals (PGM) are currently highly demanded due to their unique properties, making them indispensable in various strategic sectors such as renewable energy, electric mobility, and digital technologies. However, the high cost and dependence on importation from other countries pose significant risks for the development of strategic applications in key industrial sectors in Europe. Recognizing the critical nature of PGMs, categorized as critical raw materials (CRM) by the EC, the NICKEFFECT project has identified an opportunity to address these challenges.
In this context, NICKEFFECT aims to replace PGMs with nickel, an earth-abundant element with ferromagnetic properties. The project focuses on three key applications, such as: electrolyser electrodes, fuel cell catalysts, and magneto-electronic devices. To enhance the performance of Ni-based materials, NICKEFFECT employs innovative deposition techniques to develop coatings with ordered and pseudo-ordered porosity. The increased surface-to-volume ratio provided by these coatings is expected to enhance catalytic performance and contribute to the converse magnetoelectric effect (CME) in electronic devices. NICKEFFECT sets out to develop and validate at least three new materials, along with the corresponding coating methodologies, process modeling, and decision support tools for materials selection. These tools integrate safe and sustainable by design (SSbD) criteria and materials modeling to ensure the viability and eco-friendliness of alternatives.
The project aims to advance technology from the proof-of-concept (TRL3) to validation in real environments (TRL5). The partners elevate the technology further reaching higher TRLs and paving the way towards market-ready PGM-free coating materials and solutions in a variety of industrial applications. NICKEFFECT aligns with the objectives of the twin green and digital transformations, aiming to have a significant scientific and socio-economic impact on Europe's industrial landscape within the project duration, as well as in a long-term perspective. By focusing on safety and sustainability, NICKEFFECT seeks to contribute to resilient, sustainable, and secure raw materials value chains for EU industrial ecosystems.
In this context, NICKEFFECT aims to replace PGMs with nickel, an earth-abundant element with ferromagnetic properties. The project focuses on three key applications, such as: electrolyser electrodes, fuel cell catalysts, and magneto-electronic devices. To enhance the performance of Ni-based materials, NICKEFFECT employs innovative deposition techniques to develop coatings with ordered and pseudo-ordered porosity. The increased surface-to-volume ratio provided by these coatings is expected to enhance catalytic performance and contribute to the converse magnetoelectric effect (CME) in electronic devices. NICKEFFECT sets out to develop and validate at least three new materials, along with the corresponding coating methodologies, process modeling, and decision support tools for materials selection. These tools integrate safe and sustainable by design (SSbD) criteria and materials modeling to ensure the viability and eco-friendliness of alternatives.
The project aims to advance technology from the proof-of-concept (TRL3) to validation in real environments (TRL5). The partners elevate the technology further reaching higher TRLs and paving the way towards market-ready PGM-free coating materials and solutions in a variety of industrial applications. NICKEFFECT aligns with the objectives of the twin green and digital transformations, aiming to have a significant scientific and socio-economic impact on Europe's industrial landscape within the project duration, as well as in a long-term perspective. By focusing on safety and sustainability, NICKEFFECT seeks to contribute to resilient, sustainable, and secure raw materials value chains for EU industrial ecosystems.
Following the successful laboratory-scale developments, the project activities progressed toward defining and realizing scale-up processes, advancing the development of sustainable, high-performance Ni-based coatings for strategic applications in energy and data storage technologies.
For catalytic applications, Ni-based coatings were synthesized using chemical, physical and physico-chemical methods. The developed material demonstrated high activity for the hydrogen evolution reaction (HER) and oxygen reduction reaction (ORR), achieving up to 85% platinum group metal (PGM) reduction in PEM electrolyzers and fuel cells. The scale-up was supported by advanced fabrication process models, accurately reflecting real system features and enabling predictive optimization of coating processes. A computer-based model for micro-scale electrodeposition, integrated into the MIoTraS platform, was validated on complex 3D substrates. Complementary tools for quantitative surface analysis were also developed.
In the information and communication technologies sector, multilayered [Co/Ni] coatings were designed for MRAM applications. These coatings demonstrated magneto-ionic tunability and stability under voltage cycling. Integration into full MRAM stacks has been successfully initiated.
Materials design was accelerated through machine learning and DFT-based modelling, identifying key performance descriptors for catalytic and magnetic properties, thereby guiding experimental synthesis. Validation of demonstrators by end-users is ongoing across all use cases.
A major project’s achievement is the development of an expanded materials database ensuring all data and results are stored with full traceability, following FAIR principles, and a modular decision support tool. While still under development, this tool integrates chemical risk assessment, environmental impact analysis, and machine learning capabilities to support safe and sustainable material design.
For catalytic applications, Ni-based coatings were synthesized using chemical, physical and physico-chemical methods. The developed material demonstrated high activity for the hydrogen evolution reaction (HER) and oxygen reduction reaction (ORR), achieving up to 85% platinum group metal (PGM) reduction in PEM electrolyzers and fuel cells. The scale-up was supported by advanced fabrication process models, accurately reflecting real system features and enabling predictive optimization of coating processes. A computer-based model for micro-scale electrodeposition, integrated into the MIoTraS platform, was validated on complex 3D substrates. Complementary tools for quantitative surface analysis were also developed.
In the information and communication technologies sector, multilayered [Co/Ni] coatings were designed for MRAM applications. These coatings demonstrated magneto-ionic tunability and stability under voltage cycling. Integration into full MRAM stacks has been successfully initiated.
Materials design was accelerated through machine learning and DFT-based modelling, identifying key performance descriptors for catalytic and magnetic properties, thereby guiding experimental synthesis. Validation of demonstrators by end-users is ongoing across all use cases.
A major project’s achievement is the development of an expanded materials database ensuring all data and results are stored with full traceability, following FAIR principles, and a modular decision support tool. While still under development, this tool integrates chemical risk assessment, environmental impact analysis, and machine learning capabilities to support safe and sustainable material design.
The results achieved in NICKEFFECT go well beyond the current state of the art and are expected to substantially accelerate the development of sustainable alternatives to PGMs for both energy and digital applications. Pt replacement in materials for energy application has a huge impact. The obtained results represent a significant advancement. Among the project results obtained so far it is worth highlighting:
- Ni-based coatings with tuned porosity for HER. The fabrication process for the electrodes was patented (EP4575040). Industrial relevance was addressed through successful scale-up of coatings for PEM-WE and PEM-FC components (supported by computer aided engineering strategy) and initial validation in membrane-electrode assemblies.
- Development of electrodeposition process models capturing the complex 3D features of the substrate. The workflow involving both macro- and micro-scale simulations was established to allow for a correct comparison between measured and simulated results.
- The entire nucleation model is defined and implemented to simulate the real PEM FC catalysts fabrication process and enable a predictive optimization of the catalysts.
- For MRAM applications, Pt-free multilayers with controlled magnetic properties were demonstrated, those performance is comparable to Pt containing counterparts, where achieved performance KPIs pave the way towards successful commercialization.
- Modular decision support tool incorporating the chemical safety, environment impact and machine learning modules and linked to the project’s generated materials database is operative and allows the lab scientists (non-expert in SSbD) and SSbD experts to have quick and easy access to the assessments.
- Ni-based coatings with tuned porosity for HER. The fabrication process for the electrodes was patented (EP4575040). Industrial relevance was addressed through successful scale-up of coatings for PEM-WE and PEM-FC components (supported by computer aided engineering strategy) and initial validation in membrane-electrode assemblies.
- Development of electrodeposition process models capturing the complex 3D features of the substrate. The workflow involving both macro- and micro-scale simulations was established to allow for a correct comparison between measured and simulated results.
- The entire nucleation model is defined and implemented to simulate the real PEM FC catalysts fabrication process and enable a predictive optimization of the catalysts.
- For MRAM applications, Pt-free multilayers with controlled magnetic properties were demonstrated, those performance is comparable to Pt containing counterparts, where achieved performance KPIs pave the way towards successful commercialization.
- Modular decision support tool incorporating the chemical safety, environment impact and machine learning modules and linked to the project’s generated materials database is operative and allows the lab scientists (non-expert in SSbD) and SSbD experts to have quick and easy access to the assessments.