New nickel-and-carbon technology from Cornell University promises to cut costs and broaden fuel cell use

New nickel-and-carbon technology promises lower costs and wider fuel cell use

Researchers at Cornell University have created a fuel-cell catalyst that avoids expensive precious metals such as platinum and palladium. The team’s nickel catalyst, protected by a carbon coating, delivers strong performance in alkaline conditions, positioning it for broader, more affordable deployment.

Why alkaline fuel cells could reduce reliance on precious metals

Conventional fuel cells typically operate in acidic environments, where catalysts must be made from precious metals to remain stable. The price of those materials is a major barrier to wider adoption. By shifting to an alkaline environment, it becomes feasible to use far cheaper metals-such as nickel, iron and cobalt-which are around 500–1000 times less expensive.

Cornell University’s nickel–carbon (graphene) catalyst and how it works

A key obstacle for alkaline fuel cells has been the slow hydrogen oxidation reaction. Although nickel is a promising candidate, it oxidises quickly and loses catalytic activity. The researchers addressed this by covering nickel with an ultra-thin graphene-derived carbon layer only 3–4 atoms thick. This shield limits oxidation while allowing the nickel to remain active.

Power output, microscopy evidence, and durability targets

In testing, the catalyst achieved a power density of 1 W per square centimetre, exceeding US Department of Energy targets for fuel cells that rely on precious-metal catalysts. As a result, the approach is able to compete with established systems.

The catalyst was evaluated under conditions designed to mimic real fuel-cell operation. The findings indicate the carbon coating effectively blocks oxygen from reaching the nickel, helping preserve its characteristics-supported by atomic-level microscopy images.

At present, the system lasts roughly 2000 hours, below the 15,000-hour target. Even so, the researchers believe engineering refinements can deliver the required stability, since the underlying reaction chemistry has already been shown to work.

Potential uses in vehicles, generators, and decentralised power

Looking ahead, the technology could be adopted in the automotive sector as well as in stationary and portable generators. It may also suit decentralised electricity supply, particularly for remote locations.