Journal of Materials Science Research and Reviews

Despite being a potential next-generation energy device, direct methanol fuel cells (DMFCs) are not yet widely available due to their slow methanol oxidation reaction (MOR) kinetics and dependence on expensive platinum catalysts. Here, we describe the direct development of nickel cobalt oxide (NiCoO₄) nanostructures on nickel foam (NF) as a productive, binder-free catalyst for MOR in alkaline media. After a straightforward hydrothermal method and annealing, the NiCo₂O₄/NF electrode was created, and its structural and electrochemical characteristics were thoroughly examined. A porous nickel foam structure adorned with flower-shaped NiCoO₄ microspheres made from needle-like ligaments was visible in SEM images. This structure offered a high density of reactive sites and effective charge routes. While XRD patterns revealed the crystalline spinel phase of NiCo₂O₄, EDS mapping confirmed a homogenous Ni–Co–O distribution. In comparison to blank NF or single oxides, electrochemical tests showed markedly greater current densities in methanol-containing electrolytes, indicating enhanced MOR activity. In line with other studies of high-performance NiCo₂O₄ morphologies, the porous–hierarchical design allowed for excellent catalyst adhesion, strong ion transport, and long-term stability. These results demonstrate that NiCo₂O₄/NF is a non-platinum catalyst that is inexpensive, long-lasting, and has a lot of potential for improving DMFC technology. The importance of this study lies in presenting a cost-effective, non-platinum, and durable catalyst platform that addresses the key limitations of conventional DMFC electrodes, thereby advancing the practical realization of sustainable and affordable methanol fuel cell technologies.