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Supported ordered intermetallic nanoparticles are of significant interest for catalysis applications owing to their unique surface/near-surface structures and electronic properties. However, the synthesis of small-sized intermetallic catalysts with high mass activity remains a formidable challenge, as high temperatures annealing treatments are generally requisite to achieve ordered intermetallic structures but lead to undesired larger crystallites. Here, we report an industrially relevant impregnation approach for the scalable synthesis of small-sized platinum-based intermetallic nanoparticle catalysts by regulating inter-particle distance on carbon black supports to mitigate metal sintering in high-temperature annealing. We construct a library consisting of 18 binary Pt-based intermetallic nanoparticle catalysts with an average size of < 5 nm. The prepared intermetallic catalyst libraries exhibit outstanding proton-exchange-membrane fuel cells performance, including high mass activities of 1.3–1.8 A mg Pt –1, large peak power densities of 1.2–1.4 W cm–2 in H 2 -air cells, and efficient Pt utilization of ∼0.07 g kW–1 at rated power. [Display omitted] • Intermetallic compounds (IMC) have unique strain/electronic effects in catalysis. • A family of small size Pt-based IMCs was achieved by regulating inter-particle distance. • Small size and ordered IMC structure guarantee outstanding performance in fuel cell. [ABSTRACT FROM AUTHOR]

Abstract: The influence of the structure and morphology of PtRu nanoparticles supported on functionalized carbon black has been investigated for CO and methanol electrooxidation in a half-cell and in a DMFC single cell. Carbon black was treated with HNO3 to obtain an oxidized surface (Vulcan-N), and PtRu nanoparticles supported on Vulcan-N were prepared via impregnation, Bönnemann''s method and the sulfito-complex route. Temperature programmed reduction (TPR) measurements evidence the presence of RuO2·xH2O phase in the catalyst obtained by the sulfito-complex route. This phase was stabilized by metal–support interaction, whereas alloy characteristics were estimated for PtRu catalyst obtained by impregnation and Bönnemann''s method. The nature of the precursor–support interaction, induced by the nature of the functional groups on the carbon surface, affects the structure of the electrocatalyst and subsequent behavior in electroactivity. When synthesized through Bönnemann''s method, the surface oxygen-containing groups of the support seem to be unable to stabilize the anhydrous precursors of platinum and ruthenium, yielding crystalline RuO2. Methanol electrooxidation performance was clearly different in the three catalysts, whereas only a few negligible differences were observed in CO oxidation. The superior performance in DMFC of the catalysts obtained by the sulfito-complex route accounts for both the presence of RuO2·xH2O species and the functionalization of carbon black. [Copyright &y& Elsevier]