Toward industrially relevant testing of activity and stability in alkaline electrolysis electrode materials

Green hydrogen production via water electrolysis is a pivotal component of the transition to a carbon-neutral energy system. Among available technologies, alkaline water electrolysis (AWE) offers a scalable, cost-effective pathway that avoids reliance on critical raw materials such as precious metals. However, AWE systems must operate under increasingly demanding conditions such as frequent start-up and shut-down cycles driven by intermittent renewable power, which can be mitigated, however, at an increase in capital and operational costs. Furthermore, AWE systems for economic viability need to operate under high current densities. Despite this, most academic studies are still conducted at low current densities and room temperature, conditions far removed from industrial relevance. This review critically examines the limitations of such traditional testing approaches and highlights recent advances in evaluating catalyst activity and durability under industry-representative conditions: elevated temperatures (60–80°C), concentrated electrolytes (20–40 wt% KOH), and high current densities (≥1 A cm⁻²). We explore innovative laboratory-scale cell designs, three-electrode configurations for intrinsic activity screening, and custom single-cell setups that mimic commercial stacks. The importance of long-term stability testing, including accelerated stress tests simulating intermittent operation, is emphasized. Finally, the need for standardized protocols and interlaboratory validation is underscored as essential for bridging the gap between academic research and industrial deployment of robust, non-precious AWE electrodes.