New Method to Synthesize Highly Active and Durable Chemically Ordered fct-PtCo Cathode Catalyst for PEMFCs

A review of ordered PtCo3 catalyst with higher oxygen reduction reaction activity in proton exchange membrane fuel cells

This review is devoted to the potential advantages of ordered alloy catalysts in proton exchange membrane fuel cells (PEMFCs), specifically focusing on the development of the low Pt content, high activity, and durability ordered PtCo3 catalyst. Due to the sluggish oxygen reduction reaction (ORR) kinetics and poor durability, the overall performance of the fuel cell is affected, and its application and promotion are limited. To address this issue, researchers have explored various synthetic strategies, such as element doping, morphology adjusting, structure controlling, ordering and support/metal interaction enhancement. This article extensively discussed the Pt related ORR catalysts and follows an in-depth analysis of ordered PtCo3. The introduction briefly discusses the direction of development of fuel cell catalysts and frontier progress, including theoretical mechanism, practical preparation, and Pt-containing electrode structures, etc. The subsequent chapter focuses on the Pt-Co catalyst, the evolution process of Pt alloy to Pt-Co alloy and the improvement scheme are introduced. The next chapter describes the properties of PtCo3. Although the ordered PtCo3 catalyst has a wide range of applicability due to low cost and high activity catalyst. However, besides the common agglomeration and sintering problems of Pt-Co alloy, its commercial application still faces unique problems of oversized crystal size, phase segregation, ordering transformation and transition metal dissolution. Therefore, in Chapter 4, this overview provides some possible improvement methods for three specific functions: crystal refinement, enhancing the effect of support and active substances, and anti-dissolution.

Highly stable and active catalyst in fuel cells through surface atomic ordering

Shape-controlled alloy nanoparticle catalysts have been shown to exhibit improved performance in the oxygen reduction reaction (ORR) in liquid half-cells. However, translating the success to catalyst layers in fuel cells faces challenges due to the more demanding operation conditions in membrane electrode assembly (MEA). Balancing durability and activity is crucial. Here, we developed a strategy that limits the atomic diffusion within surface layers, fostering the phase transition and shape retention during thermal treatment. This enables selective transformation of platinum-iron nanowire surfaces into intermetallic structures via atomic ordering at a low temperature. The catalysts exhibit enhanced MEA stability with 50% less Fe loss while maintaining high catalytic activity comparable to that in half-cells. Density functional calculations suggest that the ordered intermetallic surface stabilizes morphology against rapid corrosion and improves the ORR activity. The surface engineering through atomic ordering presents potential for practical application in fuel cells with shape-controlled Pt-based alloy catalysts.

In-situ atomic tracking of intermetallic compound formation during thermal annealing

Intermetallic compounds (IMCs) with ordered atomic structure have gained great attention as nanocatalysts for its enhanced activity and stability. Although the reliance of IMC preparation on high-temperature annealing is well known, a comprehensive understanding of the formation mechanisms of IMCs in this process is currently lacking. Here, we employ aberration-corrected high-angle annular dark-field scanning transmission electron microscopy (AC-HAADF-STEM) to track the formation process of IMCs on carbon supports during in-situ annealing, by taking PtFe as a case study within an industry-relevant impregnation synthesis framework. We directly discern five different stages at the atomic level: initial atomic precursors; Pt cluster formation; Pt-Fe disordered alloying; structurally ordered Pt3Fe formation, and final Pt3Fe-PtFe IMC conversion. In particular, we find that the crucial role of high-temperature annealing resides in facilitating the diffusion of Fe towards Pt, enabling the creation of alloys with the targeted stoichiometric ratio, which in turn provides the thermodynamic driving force for the disorder-to-order transition.

Emerging Pt-based intermetallic nanoparticles for the oxygen reduction reaction

The advancement of highly efficient and enduring platinum (Pt)-based electrocatalysts for the oxygen reduction reaction (ORR) is a critical determinant to enable broad utilization of clean energy conversion technologies. Pt-based intermetallic electrocatalysts offer durability and superior ORR activity over their traditional analogues due to their definite stoichiometry, ordered and extended structures, and favourable enthalpy of formation. With the advent in new synthetic methods, Pt-based intermetallic nanoparticles as a new class of advanced electrocatalysts have been studied extensively in recent years. This review discusses the preparation principles, representative preparation methods of Pt-based intermetallics and their applications in the ORR. Our review is focused on L10 Pt-based intermetallics which have gained tremendous interest recently due to their larger surface strain and enhanced M(3d)-Pt(5d) orbital coupling, particularly in the crystallographic c-axis direction. Additionally, we discuss future research directions to further improve the efficiency of Pt-based intermetallic electrocatalysts with the intention of stimulating increased research ventures in this domain.

Alloying Matters for Ordering: Synthesis of Highly Ordered PtCo Intermetallic Catalysts for Fuel Cells

Porous carbon-supported atomically ordered intermetallic compounds (IMCs) are promising electrocatalysts in boosting oxygen reduction reaction (ORR) for fuel cell applications. However, the formation mechanism of IMC structures under high temperatures is poorly understood, which hampers the synthesis of highly ordered IMC catalysts with promoted ORR performance. Here, we employ high-temperature X-ray diffraction and energy-dispersive spectroscopic elemental mapping techniques to study the formation process of IMCs, by taking PtCo for example, in an industry-relevant impregnation synthesis. We find that high-temperature annealing is crucial in promoting the formation of alloy particles with a stoichiometric Co/Pt ratio, which in turn is the precondition for transforming the disordered alloys to ordered intermetallic structures at a relatively low temperature. Based on the findings, we accordingly synthesize highly ordered L1₀-type PtCo catalysts with a remarkable ORR performance in fuel cells.

Advancements in cathode catalyst and cathode layer design for proton exchange membrane fuel cells

Proton exchange membrane fuel cells have been recently developed at an increasing pace as clean energy conversion devices for stationary and transport sector applications. High platinum cathode loadings contribute significantly to costs. This is why improved catalyst and support materials as well as catalyst layer design are critically needed. Recent advances in nanotechnologies and material sciences have led to the discoveries of several highly promising families of materials. These include platinum-based alloys with shape-selected nanostructures, platinum-group-metal-free catalysts such as metal-nitrogen-doped carbon materials and modification of the carbon support to control surface properties and ionomer/catalyst interactions. Furthermore, the development of advanced characterization techniques allows a deeper understanding of the catalyst evolution under different conditions. This review focuses on all these recent developments and it closes with a discussion of future research directions in the field.

The high platinum loadings at the cathodes of proton exchange membrane fuel cells significantly contribute to the cost of these clean energy conversion devices. Here, the authors critically review and discuss recent developments on low- and non-platinum-based cathode catalysts and catalyst layers.

Subsize Pt-based intermetallic compound enables long-term cyclic mass activity for fuel-cell oxygen reduction

Pt-based alloy catalysts may promise considerable mass activity (MA) for oxygen reduction but are generally unsustainable over long-term cycles, particularly in practical proton exchange membrane fuel cells (PEMFCs). Herein, we report a series of Pt-based intermetallic compounds (Pt₃Co, PtCo, and Pt₃Ti) enclosed by ultrathin Pt skin with an average particle size down to about 2.3 nm, which deliver outstanding cyclic MA and durability for oxygen reduction. By breaking size limitation during ordered atomic transformation in Pt alloy systems, the MA and durability of subsize Pt-based intermetallic compounds can be simultaneously optimized. The subsize scale was also found to enhance the stability of the membrane electrode through preventing the poisoning of catalysts by ionomers in humid fuel-cell conditions. We anticipate that subsize Pt-based intermetallic compounds set a good example for the rational design of high-performance oxygen reduction electrocatalysts for PEMFCs. Furthermore, the prevention of ionomer poisoning was identified as the critical parameter for assembling robust commercial membrane electrodes in PEMFCs.

Anchored Pt-Co Nanoparticles on Honeycombed Graphene as Highly Durable Catalysts for the Oxygen Reduction Reaction

Durability is an important factor in evaluating the performance of a catalyst. In this work, the spatial protection of the carrier to nanoparticles was considered to improve the durability of the catalyst. It is found that a honeycombed graphene with a three-dimensional (3D)-hierarchical porous structure (3D HPG) can help to reduce the shedding of Pt-Co nanoparticles (Pt-Co NPs) because 3D HPG can form a protective layer to reduce the direct erosion of Pt-Co NPs on the interface by an electrolyte. Then, appropriate oxygen groups were introduced on the 3D reduced hierarchical porous graphene oxide (3D rHPGO) to improve the dispersion of Pt-Co NPs on the surface of the carrier. It was found that the Pt d-band of the catalyst was anchored by π sites of carbonyl of an oxygen group. After optimization, the catalyst (referred to as Pt-Co/3D rHPGO) achieved a 2-fold enhancement in mass activity than that of a commercial Pt/C catalyst. More importantly, after the accelerated durability test (ADT) of 20 000 cycles, the Pt-Co/3D rHPGO catalyst can almost sustain this level of performance, whereas other catalysts showed a comparatively large loss of activity. According to the results, the high durability of Pt-Co/3D rHPGO was attributed to spatial protection of Pt-Co NPs and the defects on the surface allowed the electrolyte to enter. In addition, oxygen groups provided an anchoring effect on nanoparticles. Thus, the Pt-Co/3D rHPGO electrocatalyst exhibited splendid durability, holding a potential to be applied in PEMFC for long-term work.

Enhanced PEMFC durability with graphitized carbon black cathode catalyst supports under accelerated stress testing

The anti-corrosion properties of the carbon substrates of cathode catalysts play a vital role in the commercialization of fuel cell vehicles. Our report reveals the enhanced durability of graphitized carbon black catalyst substrates in polymer electrolyte membrane fuel cells (PEMFCs), tested under simulated start-stop cycling and high potential holding conditions. Graphitized carbon treated at various temperatures is used as the support for Pt catalysts. The catalyst utilizing graphitized carbon treated at 1800 °C demonstrates superior antioxidation properties and the inhibition of Pt particle coarsening. The decay ratio of the potential at 1000 mA cm-2 has been reduced from 34.9% (commercial Pt/C) to 0.5% during high potential holding accelerated stress testing. Correspondingly, the growth of Pt particles is reduced from 0.95 nm (commercial Pt/C) to 0.08 nm; that is, the coalescence of Pt particles is effectively alleviated upon using graphitized carbon black.

Atomic-Level Manipulations in Oxides and Alloys for Electrocatalysis of Oxygen Evolution and Reduction

As chemical reactions and charge-transfer simultaneously occur on the catalyst surface during electrocatalysis, numerous studies have been carried out to attain an in-depth understanding on the correlation among the surface structure and composition, the electrical transport, and the overall catalytic activity. Compared with other catalysis reactions, a relatively larger activation barrier for oxygen evolution/reduction reactions (OER/ORR), where multiple electron transfers are involved, is noted. Many works over the past decade thus have been focused on the atomic-scale control of the surface structure and the precise identification of surface composition change in catalyst materials to achieve better conversion efficiency. In particular, recent advances in various analytical tools have enabled noteworthy findings of unexpected catalytic features at atomic resolution, providing significant insights toward reducing the activation barriers and subsequently improving the catalytic performance. In addition to summarizing important surface issues, including lattice defects, related to the OER and ORR in this Review, we present the current status and discuss future perspectives of oxide- and alloy-based catalysts in terms of atomic-scale observation and manipulation.

High-Loading Pt-Co/C Catalyst with Enhanced Durability toward the Oxygen Reduction Reaction through Surface Au Modification

Carbon-supported Pt-Co (Pt-Co/C) nanoparticles with a high Pt loading are regarded as promising cathode catalysts for practical applications of proton exchange membrane fuel cells (PEMFCs). Unfortunately, with high loading, it is difficult to improve the catalytic durability while maintaining the particle size between 2 and 5 nm to ensure the initial catalytic activity. Thus, it is of great significance to prepare high-loading Pt-Co/C catalysts with enhanced activity and durability. Herein, we proposed an efficient way to prepare high-Pt-loading (>50 wt %) Pt-Co/C catalysts without using any further surfactants. Furthermore, due to the one-step selective acid etching and surface Au modification, the as-prepared catalysts only need to undergo thermal treatment at as low as 150 °C to achieve a surface structure rich of Pt and Au. The average particle size of the as-prepared Au-Pt-Co/C-0.015 is 3.42 nm, and the Pt loading of it is up to 50.2 wt %. The atomic ratio of Pt, Co, and Au is 94:5:1. The mass activity (MA) is nearly 1.9 times that of Pt/C (60 wt %, JM) and the specific activity is also improved. The MA loss after the 30,000-cycle accelerated degradation test (ADT) is only 9.4%. The remarkable durability is mainly due to the surface Au modification, which can restrict the dissolution of Pt and Co. This research provides an effective synthesis strategy to prepare high-loading carbon-supported Pt-based catalysts beneficial to practical PEMFC applications.

Pt-Based Nanocrystal for Electrocatalytic Oxygen Reduction

Currently, Pt-based electrocatalysts are adopted in the practical proton exchange membrane fuel cell (PEMFC), which converts the energy stored in hydrogen and oxygen into electrical power. However, the broad implementation of the PEMFC, like replacing the internal combustion engine in the present automobile fleet, sets a requirement for less Pt loading compared to current devices. In principle, the requirement needs the Pt-based catalyst to be more active and stable. Two main strategies, engineering of the electronic (d-band) structure (including controlling surface facet, tuning surface composition, and engineering surface strain) and optimizing the reactant adsorption sites are discussed and categorized based on the fundamental working principle. In addition, general routes for improving the electrochemical surface area, which improves activity normalized by the unit mass of precious group metal/platinum group metal, and stability of the electrocatalyst are also discussed. Furthermore, the recent progress of full fuel cell tests of novel electrocatalysts is summarized. It is suggested that a better understanding of the reactant/intermediate adsorption, electron transfer, and desorption occurring at the electrolyte-electrode interface is necessary to fully comprehend these electrified surface reactions, and standardized membrane electrode assembly (MEA) testing protocols should be practiced, and data with full parameters detailed, for reliable evaluation of catalyst functions in devices.

Tuning the Electrocatalytic Oxygen Reduction Reaction Activity of Pt-Co Nanocrystals by Cobalt Concentration with Atomic-Scale Understanding

The development of a suitable catalyst for the oxygen reduction reaction (ORR), the cathode reaction of proton exchange membrane fuel cells (PEMFC), is necessary to push this technology toward widespread adoption. There have been substantial efforts to utilize bimetallic Pt-M alloys that adopt the ordered face-centered tetragonal (L1₀) phase in order to reduce the usage of precious metal, enhance the ORR performance, and improve catalyst stability. In this work, monodisperse Pt-Co nanocrystals (NCs) with well-defined size (4-5 nm) and cobalt composition (25-75 at%) were synthesized via colloidal synthesis. The transformation from the chemically disordered A1 (face-centered cubic, fcc) to the L1₀ phase was achieved via thermal annealing using both a conventional oven and a rapid thermal annealing process. The structure of the Pt-Co catalysts was characterized by a variety of techniques, including transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy in high-angle annular dark-field scanning transmission electron microscopy (STEM-EDS), small-angle X-ray scattering (SAXS), X-ray diffraction (XRD), and inductively coupled plasma-optical emission spectrometry (ICP-OES). The effects of annealing temperature on the composition-dependent degree of ordering and subsequent effect on ORR activity is described. This work provides insights regarding the optimal spatial distribution of elements at the atomic level to achieve enhanced ORR activity and stability.

Unusual strain effect of a Pt-based L10 face-centered tetragonal core in core/shell nanoparticles for the oxygen reduction reaction

Nanoparticles with a low-Pt content core and a few-layer thick Pt skin are attractive catalysts toward the oxygen reduction reaction (ORR) not only for their low cost, but also because their activity can be enhanced by judiciously choosing the core alloy.

Atomic Platinum Skin under Synergy of Cobalt for Enhanced Methanol Oxidation Electrocatalysis

To reduce the cost of the catalyst and the consumption of Pt, a facile electrochemical displacement preparation method is proposed, and the nanostructures can be easily controlled by a strong reducing agent and a surfactant. Two distinct Pt-Co spheres, Pt-Co core-shell spheres (CSSs), and Pt-Co hollow alloy spheres (HASs) were successfully synthesized by changing the introduction of N₂. Interestingly, Pt-Co CSSs possess a Pt-rich shell with 7 atomic layer thickness, which promotes the efficient utilization of Pt atoms. Pt-Co HASs have a highly open structure and a single alloy phase. For the methanol oxidation reaction, Pt-Co CSSs and Pt-Co HASs exhibit enhanced catalytic performances. Compared with the commercial Pt/C catalyst, the mass activity of the Pt-Co CSS catalyst is increased by 4 times, and it has better stability. More importantly, the current work opens a door to the batch preparation of Pt-based catalysts and synthesis of shell nanostructures.

Ordered Pt3Co Intermetallic Nanoparticles Derived from Metal-Organic Frameworks for Oxygen Reduction

Highly ordered Pt alloy structures are proven effective to improve their catalytic activity and stability for the oxygen reduction reaction (ORR) for proton exchange membrane fuel cells. Here, we report a new approach to preparing ordered Pt₃Co intermetallic nanoparticles through a facile thermal treatment of Pt nanoparticles supported on Co-doped metal-organic-framework (MOF)-derived carbon. In particular, the atomically dispersed Co sites, which are originally embedded into MOF-derived carbon, diffuse into Pt nanocrystals and form ordered Pt₃Co structures. It is very crucial for the formation of the ordered Pt₃Co to carefully control the doping content of Co into the MOFs and the heating temperatures for Co diffusion. The optimal Pt₃Co nanoparticle catalyst has achieved significantly enhanced activity and stability, exhibiting a half-wave potential up to 0.92 V vs reversible hydrogen electrode (RHE) and only losing 12 mV after 30 000 potential cycling between 0.6 and 1.0 V. The highly ordered intermetallic structure was retained after the accelerated stress tests made evident by atomic-scale elemental mapping. Fuel cell tests further verified the high intrinsic activity of the ordered Pt₃Co catalysts. Unlike the direct use of MOF-derived carbon supports for depositing Pt, we utilized MOF-derived carbon containing atomically dispersed Co sites as Co sources to prepare ordered Pt₃Co intermetallic catalysts. The new synthesis approach provides an effective strategy to develop active and stable Pt alloy catalysts by leveraging the unique properties of MOFs such as 3D structures, high surface areas, and controlled nitrogen and transition metal dopings.