3D Analysis of Fuel Cell Electrocatalyst Degradation on Alternate Carbon Supports

Nanostructure Engineering of Cathode Layers in Proton Exchange Membrane Fuel Cells: From Catalysts to Membrane Electrode Assembly

The membrane electrode assembly (MEA) is the core component of proton exchange membrane fuel cells (PEMFCs), which is the place where the reaction occurrence, the multiphase material transfer and the energy conversion, and the development of MEA with high activity and long stability are crucial for the practical application of PEMFCs. Currently, efforts are devoted to developing the regulation of MEA nanostructure engineering, which is believed to have advantages in improving catalyst utilization, maximizing three-phase boundaries, enhancing mass transport, and improving operational stability. This work reviews recent research progress on platinum group metal (PGM) and PGM-free catalysts with multidimensional nanostructures, catalyst layers (CLs), and nano-MEAs for PEMFCs, emphasizing the importance of structure-function relationships, aiming to guide the further development of the performance for PEMFCs. Then the design strategy of the MEA interface is summarized systematically. In addition, the application of in situ and operational characterization techniques to adequately identify current density distributions, hot spots, and water management visualization of MEAs is also discussed. Finally, the limitations of nanostructured MEA research are discussed and future promising research directions are proposed. This paper aims to provide valuable insights into the fundamental science and technical engineering of efficient MEA interfaces for PEMFCs.

Cathode Catalyst Layer Design in PEM Water Electrolysis toward Reduced Pt Loading and Hydrogen Crossover

Reducing the use of platinum group metals is crucial for the large-scale deployment of proton exchange membrane (PEM) water electrolysis systems. The optimization of the cathode catalyst layer and decrease of the cathode Pt loading are usually overlooked due to the predominant focus of research on the anode. However, given the close relationship between the rate of hydrogen permeation through the membrane in an operating cell and the local hydrogen concentration near the membrane-cathode interface, the structural design of the cathode catalyst layer is considered to be of pivotal importance for reducing H2 crossover, particularly in combination with the use of thin (≲50 μm) membranes. In this study, we have conducted a detailed investigation on the cathode structural parameters, covering the Pt wt % of the Pt/C electrocatalyst, the type of carbon support (Vulcan and high surface area carbon, HSAC), and the ionomer content, with a goal to reduce Pt loading to 0.025 mgPt/cm2 while minimizing the rate of cell hydrogen crossover. We found that the electrochemical performance is mainly influenced by the changes in the interfacial contact resistance due to variations in the cathode thickness. Both the Pt wt % in Pt/C and the ionomer content showed a positive correlation with the measured H2 in O2% in the anode outlet, whereas the Pt loading exhibited an opposite trend. The rate of hydrogen crossover was analyzed in relation to the calculated local volumetric current density within the cathode catalyst layer. Based on the obtained hydrogen mass transfer coefficient, a cathode catalyst layer comprising 40 wt % Pt on HSAC support with an ionomer-to-carbon (I/C) ratio of 0.35 was found to be an optimum configuration for achieving a low Pt loading of 0.025 mgPt/cm2 and a reduced rate of hydrogen crossover.

Comprehensive Molecular Dynamics Study of Oxygen Diffusion in Carbon Mesopores: Insights for Designing Fuel-Cell Catalyst Supports

Mesoporous carbon is often used as a support for platinum catalysts in polymer electrolyte fuel-cell catalyst layers. Mesopores in the carbon support improve the performance of fuel cells by inhibiting the adsorption of ionomer onto the catalyst particles. However, the mesopores may impair mass transport. Hence, understanding molecular behaviors in the pores is essential to optimizing the mesopore structures. Specifically, it is crucial to understand the oxygen transport in the high-current region. In this study, the diffusion coefficients of oxygen molecules in carbon mesopores were calculated for various pore lengths, pore diameters, filling rates, and water contents in the ionomer via molecular dynamics simulations. The results show that oxygen diffusion slows by 2 orders of magnitude because of pore occlusion, and it slows down by an additional 1 or 2 orders of magnitude if ionomers are present in the pores. The occlusion can be theoretically predicted by considering the surface free energy. This theory provides some insight into mesoporous carbon designs; for instance, the theory suggests that narrow pores should be shortened to prevent occlusion. Slow diffusion in the presence of ionomers was attributed to the localization of oxygen at the dense ionomer-carbon interface. Thus, to improve oxygen transport properties, carbon surfaces and ionomer structures may be designed in such a manner as to prevent densification at the interface.

Carbon black supported Ag nanoparticles in zero-gap CO2 electrolysis to CO enabling high mass activity

In this study Ag nanoparticles supported on carbon black (Ag/C) were studied as catalysts for the electrochemical reduction of CO₂ to CO. The nanoparticles were synthesized on three carbon supports, namely Super P, Vulcan and Ketjenblack with surface areas from 50 to 800 m² g^-1 using cysteamine as a linker as proposed by Kim et al., J. Am. Chem. Soc., 2015, 137, 13844. Gas diffusion electrodes were fabricated with all three Ag/Cs and then characterized in a zero-gap electrolyzer. All three supported catalysts achieve high voltage efficiencies, mass activities, and faradaic efficiencies above 80% up to 200 mA cm^-2 with Ag loadings of ∼0.07 mg cm^-2. Using an IrO₂ anode, a partial CO current density of 196 mA cm^-2 at 2.95 V and a mass activity of 3920 mA mg^-1 at a cell voltage of 3.2 V was achieved. When changing the electrolyte from 0.1 M KOH to 0.1 M CsOH, it is possible to achieve 90% FE_CO at 300 mA cm^-2. This results in a mass activity up to 5400 mA mg^-1. Moreover, long-term tests at 300 mA cm^-2 with 0.1 M CsOH resulted in FE_CO remaining above 80% over 11 h. The electrochemical performance did not show a dependence on the carbon support, indicating that mass transport is limiting the cathode, rather than catalyst kinetics. It is worth noting that this may only apply to electrodes with PTFE binders as used in this study, and electrodes with ionomer binders may show a dependence on the catalyst support.

Three-dimensional nanoimaging of fuel cell catalyst layers

Catalyst layers in proton exchange membrane fuel cells consist of platinum-group-metal nanocatalysts supported on carbon aggregates, forming a porous structure through which an ionomer network percolates. The local structural character of these heterogeneous assemblies is directly linked to the mass-transport resistances and subsequent cell performance losses; its three-dimensional visualization is therefore of interest. Herein we implement deep-learning-aided cryogenic transmission electron tomography for image restoration, and we quantitatively investigate the full morphology of various catalyst layers at the local-reaction-site scale. The analysis enables computation of metrics such as the ionomer morphology, coverage and homogeneity, location of platinum on the carbon supports, and platinum accessibility to the ionomer network, with the results directly compared and validated with experimental measurements. We expect that our findings and methodology for evaluating catalyst layer architectures will contribute towards linking the morphology to transport properties and overall fuel cell performance.

Controlled Synthesis of Carbon-Supported Pt-Based Electrocatalysts for Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells are playing an increasing role in postpandemic economic recovery and climate action plans. However, their performance, cost, and durability are significantly related to Pt-based electrocatalysts, hampering their large-scale commercial application. Hence, considerable efforts have been devoted to improving the activity and durability of Pt-based electrocatalysts by controlled synthesis in recent years as an effective method for decreasing Pt use, and consequently, the cost. Therefore, this review article focuses on the synthesis processes of carbon-supported Pt-based electrocatalysts, which significantly affect the nanoparticle size, shape, and dispersion on supports and thus the activity and durability of the prepared electrocatalysts. The reviewed processes include (i) the functionalization of a commercial carbon support for enhanced catalyst–support interaction and additional catalytic effects, (ii) the methods for loading Pt-based electrocatalysts onto a carbon support that impact the manufacturing costs of electrocatalysts, (iii) the preparation of spherical and nonspherical Pt-based electrocatalysts (polyhedrons, nanocages, nanoframes, one- and two-dimensional nanostructures), and (iv) the postsynthesis treatments of supported electrocatalysts. The influences of the supports, key experimental parameters, and postsynthesis treatments on Pt-based electrocatalysts are scrutinized in detail. Future research directions are outlined, including (i) the full exploitation of the potential functionalization of commercial carbon supports, (ii) scaled-up one-pot synthesis of carbon-supported Pt-based electrocatalysts, and (iii) simplification of postsynthesis treatments. One-pot synthesis in aqueous instead of organic reaction systems and the minimal use of organic ligands are preferred to simplify the synthesis and postsynthesis treatment processes and to promote the mass production of commercial carbon-supported Pt-based electrocatalysts.

Graphical Abstract

This review focuses on the synthesis process of Pt-based electrocatalysts/C to develop aqueous one-pot synthesis at large-scale production for PEMFC stack application.

Evaluation of functional layers thinning of high temperature polymer electrolyte membrane fuel cells after long term operation

The operation related degradation processes of high temperature polymer electrolyte membrane fuel cell operated with hydrogen-rich reformate gas are studied. CO impurities from the reformate gas are strongly adsorbed by the catalyst surface, leading to poisoning and thus, reduction of the overall performance of the cell. Most of the studies are performed in a laboratory set-up by applying accelerated stress tests. In the present work, a high temperature polymer electrolyte membrane fuel cell is operated in a realistic configuration for 12 000 h (500 days). The fuel cell contains as electrocatalyst Pt in the cathode and a Pt-Ru alloy in the anode. The study of the degradation occurring in the functional layers, i.e. in different regions of cathode, anode and membrane layer, is carried out by scanning electron microscopy, (scanning) transmission electron microscopy and energy dispersive X-ray spectroscopy. We observed a thinning of the functional layers and a redistribution of catalyst material. The thinning of the cathode side is larger compared to the anode side due to harsher operation conditions likely causing a degradation of the support material via C corrosion and/or due to a degradation of the catalyst via oxidation of Pt and Ru. A thinning of the membrane caused by oxidation agents is also detected. Moreover, during operation, catalyst material is dissolved at the cathode side and redistributed. Our results will help to design and develop fuel cells with higher performance.

Impact of Platinum Primary Particle Loading on Fuel Cell Performance: Insights from Catalyst/Ionomer Ink Interactions

A variety of electrochemical energy conversion technologies, including fuel cells, rely on solution-processing techniques (via inks) to form their catalyst layers (CLs). The CLs are heterogeneous structures, often with uneven ion-conducting polymer (ionomer) coverage and underutilized catalysts. Various platinum-supported-on-carbon colloidal catalyst particles are used, but little is known about how or why changing the primary particle loading (PPL, or the weight fraction of platinum of the carbon-platinum catalyst particles) impacts performance. By investigating the CL gas-transport resistance and zeta (ζ)-potentials of the corresponding inks as a function of PPL, a direct correlation between the CL high current density performance and ink ζ-potential is observed. This correlation stems from likely changes in ionomer distributions and catalyst-particle agglomeration as a function of PPL, as revealed by pH, ζ-potential, and impedance measurements. These findings are critical to unraveling the ionomer distribution heterogeneity in ink-based CLs and enabling enhanced Pt utilization and improved device performance for fuel cells and related electrochemical devices.

Identification of Catalytic Active Sites for Durable Proton Exchange Membrane Fuel Cell: Catalytic Degradation and Poisoning Perspectives

Recent progress in synthetic strategies, analysis techniques, and computational modeling assist researchers to develop more active catalysts including metallic clusters to single-atom active sites (SACs). Metal coordinated N-doped carbons (M-N-C) are the most auspicious, with a large number of atomic sites, markedly performing for a series of electrochemical reactions. This perspective sums up the latest innovative and computational comprehension, while giving credit to earlier/pioneering work in carbonaceous assembly materials towards robust electrocatalytic activity for proton exchange membrane fuel cells via inclusive performance assessment of the oxygen reduction reaction (ORR). M-N_x -C_y are exclusively defined active sites for ORR, so there is a unique possibility to intellectually design the relatively new catalysts with much improved activity, selectivity, and durability. Moreover, some SACs structures provide better performance in fuel cells testing with long-term durability. The efforts to understand the connection in SACs based M-N_x -C_y moieties and how these relate to catalytic ORR performance are also conveyed. Owing to comprehensive practical application in the field, this study has covered very encouraging aspects to the current durability status of M-N-C based catalysts for fuel cells followed by degradation mechanisms such as macro-, microdegradation, catalytic poisoning, and future challenges.

Well entrapped platinum-iron nanoparticles on three-dimensional nitrogen-doped ordered mesoporous carbon as highly efficient and durable catalyst for oxygen reduction and zinc-air battery

The high-performance and durable oxygen reduction reaction (ORR) catalyst on air cathode is a key component in assembly of Zn-air batteries. Herein, three-dimensional N-doped ordered mesoporous carbon (3D N-OMC) was first prepared with silica as a template via pyrolysis with assistance of dicyandiamide as a N-doping agent, combined by full adsorption of platinum (II) acetylacetonate (Pt(acac)₂) and iron (II) phthalocyanine (FePc) via π-π interactions. After further pyrolysis of the resulting mixture, many PtFe nanoparticles were efficiently incorporated in 3D N-OMC (termed as PtFe@3D N-OMC for simplicity). Control experiments were certificated the important role of the pyrolysis temperature played in this synthesis. The resultant composite synergistically combines advantages of hierarchically accessible surfaces, highly open structure, and well-dispersed PtFe particles, which endow the PtFe@3D N-OMC with onset and half-wave potentials of 0.98 and 0.86 V in alkaline media, respectively, showing appealing catalytic activity for the ORR. Most significantly, the PtFe@3D N-OMC based Zn-air battery has a high power density of 80.57 mW cm^-2 and long-term durability (220 h, 660 cycles). This work opens a new avenue for design of high-efficiency and durable ORR electrocatalysts in energy conversion and storage systems.

Recent Progress on Revealing 3D Structure of Electrocatalysts Using Advanced 3D Electron Tomography: A Mini Review

Electrocatalysis plays a key role in clean energy innovation. In order to design more efficient, durable and selective electrocatalysts, a thorough understanding of the unique link between 3D structures and properties is essential yet challenging. Advanced 3D electron tomography offers an effective approach to reveal 3D structures by transmission electron microscopy. This mini-review summarizes recent progress on revealing 3D structures of electrocatalysts using 3D electron tomography. 3D electron tomography at nanoscale and atomic scale are discussed, respectively, where morphology, composition, porous structure, surface crystallography and atomic distribution can be revealed and correlated to the performance of electrocatalysts. (Quasi) in-situ 3D electron tomography is further discussed with particular focus on its impact on electrocatalysts’ durability investigation and post-treatment. Finally, perspectives on future developments of 3D electron tomography for eletrocatalysis is discussed.

Noble Metal-Based Multimetallic Nanoparticles for Electrocatalytic Applications

Noble metal-based multimetallic nanoparticles (NMMNs) have attracted great attention for their multifunctional and synergistic effects, which offer numerous catalytic applications. Combined experimental and theoretical studies have enabled formulation of various design principles for tuning the electrocatalytic performance through controlling size, composition, morphology, and crystal structure of the nanoparticles. Despite significant advancements in the field, the chemical synthesis of NMMNs with ideal characteristics for catalysis, including high activity, stability, product-selectivity, and scalability is still challenging. This review provides an overview on structure-based classification and the general synthesis of NMMN electrocatalysts. Furthermore, postsynthetic treatments, such as the removal of surfactants to optimize the activity, and utilization of NMMNs onto suitable support for practical electrocatalytic applications are highlighted. In the end, future direction and challenges associated with the electrocatalysis of NMMNs are covered.

Scalable Sacrificial Templating to Increase Porosity and Platinum Utilisation in Graphene-Based Polymer Electrolyte Fuel Cell Electrodes

Polymer electrolyte fuel cells hold great promise for a range of applications but require advances in durability for widespread commercial uptake. Corrosion of the carbon support is one of the main degradation pathways; hence, corrosion-resilient graphene has been widely suggested as an alternative to traditional carbon black. However, the performance of bulk graphene-based electrodes is typically lower than that of commercial carbon black due to their stacking effects. This article reports a simple, scalable and non-destructive method through which the pore structure and platinum utilisation of graphene-based membrane electrode assemblies can be significantly improved. Urea is incorporated into the catalyst ink before deposition, and is then simply removed from the catalyst layer after spraying by submerging the electrode in water. This additive hinders graphene restacking and increases porosity, resulting in a significant increase in Pt utilisation and current density. This technique does not require harsh template etching and it represents a pathway to significantly improve graphene-based electrodes by introducing hierarchical porosity using scalable liquid processes.

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.

Theoretical research on the oxidation mechanism of doped carbon based catalysts for oxygen reduction reaction

To understand the essential reasons of poor durability and rapid initial performance loss of heteroatom doped graphene catalysts during the electrochemical oxygen reduction reaction (ORR) process, it is necessary to explore the detailed mechanism of carbon active site oxidation reaction (COR) at different electrode potentials, as it may greatly influence the ORR activity. Herein, density functional theory (DFT) calculation is used to investigate all possible COR mechanisms, including Direct-COR and Indirect-COR, on four typical doped-graphene, and understand the competing relation between COR and ORR from a thermodynamic point of view. Our systematic calculations found that the Direct-COR is affected directly by the structural stability of doped-graphene relative to pure graphite, and the Indirect-COR can be accelerated largely by the ORR process due to the ORR intermediate, such as O and OOH. The competition relation between COR and ORR is mainly influenced by the interaction between the doped-graphene and reaction species, stability of doped-structure, ORR mechanism, and electrode potential. For COR, the partial oxidation of doped-graphene is the dominant oxidation reaction compared to complete oxidation in the ORR potential range. More importantly, both partial and complete oxidation of doped-graphene can remarkably depress the ORR activity. Hence, COR should be one of the major contributors to the rapid initial performance loss of carbon based catalysts in stability testing. Our results provide a comprehensive and deep understanding of the oxidation of carbon active sites on doped-graphene surfaces and can guide the design of more robust doped-carbon based catalysts.

Elucidating the Dynamic Nature of Fuel Cell Electrodes as a Function of Conditioning: An ex Situ Material Characterization and in Situ Electrochemical Diagnostic Study

To increase the commercialization of fuel cell electric vehicles, it is imperative to improve the activity and performance of electrocatalysts through combined efforts focused on material characterization and device-level integration. Obtaining fundamental insights into the ongoing structural and compositional changes of electrocatalysts is crucial for not only transitioning an electrode from its as-prepared to functional state, also known as "conditioning", but also for establishing intrinsic electrochemical performances. Here, we investigated several oxygen reduction reaction (ORR) electrocatalysts via in situ and ex situ characterization techniques to provide fundamental insights into the interfacial phenomena that enable peak ORR mass activity and high current density performance. A mechanistic understanding of a fuel cell conditioning procedure is described, which encompasses voltage cycling and subsequent voltage recovery (VR) steps at low potential. In particular, ex situ membrane electrode assembly characterization using transmission electron microscopy and ultra-small angle X-ray scattering were performed to determine changes in carbon and Pt particle size and morphology, while in situ electrochemical diagnostics were performed either during or after specific points in the testing protocol to determine the electrochemical and interfacial changes occurring on the catalyst surface responsible for oxygen transport resistances through ionomer films. The results demonstrate that the voltage cycling (break-in) step aids in the removal of sulfate and fluoride and concomitantly reduces non-Fickian oxygen transport resistances, especially for catalysts where Pt is located within the pores of the carbon support. Subsequent low voltage holds at low temperature and oversaturated conditions, i.e., VR cycles, serve to improve mass activities by a factor of two to three, through a combined removal of contaminants, surface-blocking species (e.g., oxides), and rearrangement of the catalyst atomic structure (e.g., Pt-Pt and Pt-Co coordination).

In Situ and Operando Characterization of Proton Exchange Membrane Fuel Cells

For proton exchange membrane fuel cells (PEMFCs) to become a mainstream energy source, significant improvements in their performance, durability, and efficiency are necessary. To improve their durability, there must be a solid understanding of how the structural and electrochemical processes are affected during operation to propose mitigation strategies. To this aim, in situ and operando characterization techniques can locally identify structural and electrochemical processes, which cannot be captured using conventional techniques. Linking these properties in the same geometric area has been challenging due to its inherent limitations, such as sample size and imaging resolution. This has created a knowledge gap in structure-to-electrochemical performance relationships as operation and degradation unevenly affect different areas of the cell. In the recent past, catalyst layer degradation, hot spots, and water management have been structurally and electrochemically visualized in the same geometric area, revealing new interactions. To further the research in this direction, these interconnected fields are reviewed, followed by a roadmap for in situ characterization of PEMFCs, treating structural and electrochemical processes as a unified subject. With this approach, the knowledge of the degradation of PEMFCs will be significantly improved.

Four-dimensional joint visualization of electrode degradation and liquid water distribution inside operating polymer electrolyte fuel cells

Understanding of degradation mechanisms present in polymer electrolyte fuel cells (PEFCs) is important to continue the integration of this clean energy technology into everyday life. Further comprehension of the interaction between various components during fuel cell operation is also critical in this context. In this work, a four-dimensional operando X-ray computed tomography method is developed for combined visualization of all PEFC components as well as transient water distribution residing in the cell, which results as a by-product of the electrochemical reaction. Time resolved, identical-location visualization through degradation stages is uniquely enabled by the non-invasive and non-destructive qualities of this method. By applying an accelerated stress test that targets cathode catalyst layer (CCL) corrosion, novel observations resulting from morphological changes of the CCL such as reduction in the water volume in the adjacent gas diffusion layer, CCL crack formation and propagation, membrane swelling, as well as quantification of local carbon loss is achieved. Additionally, insight into features that contribute to reduced fuel cell performance is enabled by the use of this specialized imaging technique, such as increased membrane undulation causing delamination and separation of the CCL from the microporous layer, which greatly affects liquid water pathways and overall device performance.

Top-Down Synthesis of Nanostructured Platinum-Lanthanide Alloy Oxygen Reduction Reaction Catalysts: Pt xPr/C as an Example

The oxygen reduction reaction (ORR) is of great interest for future sustainable energy conversion and storage, especially concerning fuel cell applications. The preparation of active, affordable, and scalable electrocatalysts and their application in fuel cell engines of hydrogen cars is a prominent step toward the reduction of air pollution, especially in urban areas. Alloying nanostructured Pt with lanthanides is a promising approach to enhance its catalytic ORR activity, whereby the development of a simple synthetic route turned out to be a nontrivial endeavor. Herein, for the first time, we present a successful single-step, scalable top-down synthetic route for Pt-lanthanide alloy nanoparticles, as witnessed by the example of Pr-alloyed Pt nanoparticles. The catalyst was characterized by high-resolution transmission electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and photoelectron spectroscopy, and its electrocatalytic oxygen reduction activity was investigated using a rotating disk electrode technique. Pt _xPr/C showed ∼3.5 times higher [1.96 mA/cm²_Pt, 0.9 V vs reversible hydrogen electrode (RHE)] specific activity and ∼1.7 times higher (0.7 A/mg_Pt, 0.9 V vs RHE) mass activity compared to commercial Pt/C catalysts. On the basis of previous findings and characterization of the Pt _xPr/C catalyst, the activity improvement over commercial Pt/C originates from a lattice strain introduced by the alloying process.

Rheological Investigation on the Microstructure of Fuel Cell Catalyst Inks

We present a rheological investigation of fuel cell catalyst inks. The effects of ink parameters, which include carbon black-support structure, Pt presence on carbon support (Pt-carbon), and ionomer (Nafion) concentration, on the ink microstructure of catalyst inks were studied using rheometry in combination with ultrasmall-angle X-ray scattering (USAXS) and dynamic light scattering (DLS). Dispersions of a high-surface-area carbon (HSC), or Ketjen black type, demonstrated a higher viscosity than Vulcan XC-72 carbon due to both a higher internal porosity and a more agglomerated structure that increased the effective particle volume fraction of the inks. The presence of Pt catalyst on both the carbon supports reduced the viscosity through electrostatic stabilization. For carbon-only dispersions (without Pt), the addition of ionomer up to a critical concentration decreased the viscosity due to electrosteric stabilization of carbon agglomerates. However, with Pt-carbon dispersions, the addition of ionomer showed contrasting behavior between Vulcan and HSC supports. In the Pt-Vulcan dispersions, the effect of ionomer addition on the rheology was qualitatively similar to Vulcan dispersions without Pt. The Pt-HSC dispersions showed an increased viscosity with ionomer addition and a strong shear-thinning nature, indicating that Nafion likely flocculated the Pt-HSC aggregates. These results were verified using DLS and USAXS. Further, the observations of the effect of ionomer:carbon ratio and a comparison between carbons of different surface areas provided insights on the microstructure of the catalyst ink corresponding to the optimized I/ C ratio for fuel cell performance reported in the literature.