Optimal coordination-site exposure engineering in porous platinum for outstanding oxygen reduction performance

Coupling Single-Atom Sites and Ordered Intermetallic PtM Nanoparticles for Efficient Catalysis in Fuel Cells

The design of an efficient catalytic system with low Pt loading and excellent stability for the acidic oxygen reduction reaction is still a challenge for the extensive application of proton-exchange membrane fuel cells. Here, a gas-phase ordered alloying strategy is proposed to construct an effective synergistic catalytic system that blends PtM intermetallic compounds (PtM IMC, M = Fe, Cu, and Ni) and dense isolated transition metal sites (M-N4 ) on nitrogen-doped carbon (NC). This strategy enables Pt nanoparticles and defects on the NC support to timely trap flowing metal salt without partial aggregation, which is attributed to the good diffusivity of gaseous transition metal salts with low boiling points. In particular, the resulting Pt1 Fe1 IMC cooperating with Fe-N4 sites achieves cooperative oxygen reduction with a half-wave potential up to 0.94 V and leads to a high mass activity of 0.51 A  mgPt -1 and only 23.5% decay after 30 k cycles, both of which exceed DOE 2025 targets. This strategy provides a method for reducing Pt loading in fuel cells by integrating Pt-based intermetallics and single transition metal sites to produce an efficient synergistic catalytic system.

Bubble-Mediated Large-Scale Hierarchical Assembly of Ultrathin Pt Nanowire Network Monolayer at Gas/Liquid Interfaces

Extensive macroscale two-dimensional (2-D) platinum (Pt) nanowire network (NWN) sheets are created through a hierarchical self-assembly process with the aid of biomolecular ligands. The Pt NWN sheet is assembled from the attachment growth of 1.9 nm-sized 0-D nanocrystals into 1-D nanowires featuring a high density of grain boundaries, which then interconnect to form monolayer network structures extending into centimeter-scale size. Further investigation into the formation mechanism reveals that the initial emergence of NWN sheets occurs at the gas/liquid interfaces of the bubbles produced by sodium borohydride (NaBH₄) during the synthesis process. Upon the rupture of these bubbles, an exocytosis-like process releases the Pt NWN sheets at the gas/liquid surface, which subsequently merge into a continuous monolayer Pt NWN sheet. The Pt NWN sheets exhibit outstanding oxygen reduction reaction (ORR) activities, with specific and mass activities 12.0 times and 21.2 times greater, respectively, than those of current state-of-the-art commercial Pt/C electrocatalysts.

Designing fuel cell catalyst support for superior catalytic activity and low mass-transport resistance

The development of low-Platinum content polymer electrolyte fuel cells (PEFCs) has been hindered by inexplicable reduction of oxygen reduction reaction (ORR) activity and unexpected O₂ mass transport resistance when catalysts have been interfaced with ionomer in a cathode catalyst layer. In this study, we introduce a bottom-up designed spherical carbon support with intrinsic Nitrogen-doping that permits uniform dispersion of Pt catalyst, which reproducibly exhibits high ORR mass activity of 638 ± 68 mA mg_Pt⁻¹ at 0.9 V and 100% relative humidity (RH) in a membrane electrode assembly. The uniformly distributed Nitrogen-functional surface groups on the carbon support surface promote high ionomer coverage directly evidenced by high-resolution electron microscopy and nearly humidity-independent double layer capacitance. The hydrophilic nature of the carbon surface appears to ensure high activity and performance for operation over a broad range of RH. The paradigm challenging large carbon support (~135 nm) combined with favourable ionomer film structure, hypothesized recently to arise from the interactions of an ionic moiety of the ionomer and Nitrogen-functional group of the catalyst support, results in an unprecedented low local oxygen transport resistance (5.0 s cm⁻¹) for ultra-low Pt loading (34 ± 2 μg_Pt cm⁻²) catalyst layer.

Development of high-performance polymer electrolyte fuel cells has historically focused on designing new catalysts and ionomers. Here, the authors present a bottom-up approach for designing catalyst support that achieves superior oxygen reduction activity and low local oxygen transport resistance in a membrane electrode assembly.

Learning from the Heterogeneity at Electrochemical Interfaces

Understanding the structure-activity relationship at electrochemical interfaces is crucial in improving the performance of practical electrochemical devices, ranging from fuel cells, electrolyzers, and batteries to electrochemical sensors. However, functional electrochemical interfaces are often complex and contain various surface structures, creating heterogeneity in electrochemical activity. In this Perspective, we highlight the role of heterogeneity in electrochemistry, especially in the context of electrocatalysis. Current methods for revealing the heterogeneity at electrochemical interfaces, including nanoelectrochemistry tools and single-entity approaches, are discussed. Lastly, we provide perspectives on what one can learn by studying heterogeneity and how one can use heterogeneity to design more efficient electrochemical devices.

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.

Direct Integration of Strained-Pt Catalysts into Proton-Exchange-Membrane Fuel Cells with Atomic Layer Deposition

The design and fabrication of lattice-strained platinum catalysts achieved by removing a soluble core from a platinum shell synthesized via atomic layer deposition, is reported. The remarkable catalytic performance for the oxygen reduction reaction (ORR), measured in both half-cell and full-cell configurations, is attributed to the observed lattice strain. By further optimizing the nanoparticle geometry and ionomer/carbon interactions, mass activity close to 0.8 A mg_Pt ^-1 @0.9 V iR-free is achievable in the membrane electrode assembly. Nevertheless, active catalysts with high ORR activity do not necessarily lead to high performance in the high-current-density (HCD) region. More attention shall be directed toward HCD performance for enabling high-power-density hydrogen fuel cells.

Active Site Engineering in Porous Electrocatalysts

Electrocatalysis is at the center of many sustainable energy conversion technologies that are being developed to reduce the dependence on fossil fuels. The past decade has witnessed significant progresses in the exploitation of advanced electrocatalysts for diverse electrochemical reactions involved in electrolyzers and fuel cells, such as the hydrogen evolution reaction (HER), the oxygen reduction reaction (ORR), the CO₂ reduction reaction (CO₂ RR), the nitrogen reduction reaction (NRR), and the oxygen evolution reaction (OER). Herein, the recent research advances made in porous electrocatalysts for these five important reactions are reviewed. In the discussions, an attempt is made to highlight the advantages of porous electrocatalysts in multiobjective optimization of surface active sites including not only their density and accessibility but also their intrinsic activity. First, the current knowledge about electrocatalytic active sites is briefly summarized. Then, the electrocatalytic mechanisms of the five above-mentioned reactions (HER, ORR, CO₂ RR, NRR, and OER), the current challenges faced by these reactions, and the recent efforts to meet these challenges using porous electrocatalysts are examined. Finally, the future research directions on porous electrocatalysts including synthetic strategies leading to these materials, insights into their active sites, and the standardized tests and the performance requirements involved are discussed.

Bimetallic PtAu electrocatalysts for the oxygen reduction reaction: challenges and opportunities

Highly active, durable oxygen reduction reaction (ORR) electrocatalysts have an essential role in promoting the continuous operation of advanced energy technologies such as fuel cells and metal-air batteries. Considering the scarce reserve of Pt and its unsatisfactory overall performance, there is an urgent demand for the development of new generation ORR electrocatalysts that are substantially better than the state-of-the-art supported Pt-based nanocatalysts, such as Pt/C. Among various nanostructures, bimetallic PtAu represents one unique alloy system where highly contradictory performance has been reported. While it is generally accepted that Au may contribute to stabilizing Pt, its role in modulating the intrinsic activity of Pt remains unclear. This perspective will discuss critical structural issues that affect the intrinsic ORR activities of bimetallic PtAu, with an eye on elucidating the origin of seemingly inconsistent experimental results from the literature. As a relatively new class of electrodes, we will also highlight the performance of dealloyed nanoporous gold (NPG) based electrocatalysts, which allow a unique combination of structural properties highly desired for this important reaction. Finally, we will put forward the challenges and opportunities for the incorporation of these advanced electrocatalysts into membrane electrode assemblies (MEA) for actual fuel cells.