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An oxygen reduction reaction (ORR) is the key half reaction of proton exchange membrane fuel cells (PEMFCs), and is highly dependent on Pt-based nanocrystals as core electrocatalysts. Despite the exceptional ORR activity from adjusting the electronic structures of surface or near-surface atoms, several serious issues, including the corrosion of carbon supports, the preferential leaching of active metal elements, the instability of surface low-coordinated atoms and the sintering/agglomeration of nanocrystals, still exist, challenging the ORR durability of developed Pt-based ORR catalysts. From the point of view of the catalyst structure design, in this review, we summarized the state-of-the-art structural regulation strategies for improving the ORR durability of Pt-based catalysts. The current limitation of Pt-based binary catalysts for ORR electrocatalysis is firstly discussed, and the detailed strategies are further classified into the optimization of supports, metal-doped alloys, core/shell structures, intermetallics and high-entropy alloys, etc. The structure–performance relationship is detailedly explained, especially emphasizing the elimination of the above restrictions. Finally, the existing challenges and future research direction are further presented, aiming at practicing the PEMFC devices of the ultradurable Pt-based catalysts. [ABSTRACT FROM AUTHOR]

• Resonance structure as substrate molecules are introduced to form highly ordered PtCo alloys. • Synthesis of PtM (Co, Fe, Ni) ordered alloys use the same low temperature heat treatment conditions. • The ordered PtCo shows efficient electrocatalytic performance. Platinum-based ordered alloys have excellent catalytic performance for the cathodic oxygen reduction reaction (ORR) in fuel cells. However, these alloys exhibit a lower degree of ordering and larger crystal grains after heat treatment. Herein, a series of cyanamide group molecules (cyanamide, dicyandiamide, melamine) was employed as substrates to modify Pt-based alloys by promoting the binding between metal ions, leading to the preparation of ∼ 4 nm PtM (M = Co, Fe, Ni) ordered alloys after heat treatment. Among them, the PtCo ordered alloy prepared using hydrolyzed cyanamide with a unique resonance structure exhibits a high degree of order (93.1 %), and its mass activity of 0.915 A mg Pt -1 at 0.9 V is superior to that of Pt/C. The theoretically calculated adsorption energies of these alloys demonstrate that the resonance structure of the cyanamide substrate is beneficial for alloy formation, thereby facilitating ordered alloy synthesis. [ABSTRACT FROM AUTHOR]

Designing efficient and stable single-atom catalysts (SACs) for the oxygen reduction reaction (ORR) is essential to promote fuel cell commercialization. In this study, the Bayesian Regularization Neural Network (BRNN) has been used to determine the carbothermal shock (CTS) conditions for preparing high-loading Pt-Fe/C SACs. The BRNN model effectively identified a low reaction temperature of 283 °C for achieving high-loading (15 wt %) Pt-Fe/C SACs. Based on this model, we successfully synthesized Pt-Fe/C SACs with a metal mass content of 11.31 wt % using the CTS method. These ultrahigh content metal Pt-Fe/C SACs consisted of dispersed single atoms and foam-like atomic constructions, namely Pt-Fe/C atom foam catalysts (AFCs), rendered them promising candidates for electrocatalysis applications. The Pt-Fe/C AFCs exhibited good catalytic activity and durability toward ORR in alkaline conditions. The Pt-Fe/C AFCs were employed in a direct borohydride fuel cell (DBFC) as cathode catalyst, which resulted in a maximum power density of 214 mW cm−2 at 60 °C and demonstrated stable discharge for 40 h at room temperature. The electrocatalytic performance of the Pt-Fe/C AFCs surpassed that of low-loading Pt-Fe/C SACs and commercial Pt/C catalysts. The rapid ramp-up rate and the rapid cooling rate of the CTS process enabled the incorporation of high-loading Pt and Fe metal atoms into the graphitized carbon layer, resulting in an increased number of active sites of the Pt-Fe/C AFCs. This work provides an effective strategy for manufacturing efficient and stable SACs for practical applications in fuel cells. [Display omitted] • The Bayesian Regularization Neural Network is used to determine the CTS conditions. • Pt-Fe/C AFCs with metal content of 11.31 wt % is successfully synthesize by the CTS method. • The Pt-Fe/C AFCs exhibit good catalytic activity and durability towards ORR. • The DBFC using Pt-Fe/C AFCs cathode achieves a maximum power density of 214 mW cm−2. [ABSTRACT FROM AUTHOR]