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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]

We propose a new design for electrocatalysts consisting of two electrocatalysts (platinum and iron oxide) that are deposited on the surfaces of an oxidized graphene substrate. This design is based on a simple structure where the catalysts were deposited separately on both sides of oxidized graphene substrate; while the iron oxide precipitated out of the etching solution on the bottom-side, the surface of the oxidized graphene substrate was decorated with platinum using the atomic layer deposition technique. The Fe2O3-decorated CVD-graphene composite exhibited better hydrogen electrooxidation performance (area-normalized electrode resistance (ANR) of ~600 Ω·cm−2) and superior stability in comparison with bare-graphene samples (ANR of ~5800 Ω·cm−2). Electrochemical impedance measurements in humidified hydrogen at 240 °C for (Fe2O3|Graphene|Platinum) electrodes show ANR of ~0.06 Ω·cm−2 for a platinum loading of ~60 µgPt·cm−2 and Fe2O3 loading of ~2.4 µgFe·cm−2, resulting in an outstanding mass normalized activity of almost 280 S·mgPt−1, exceeding even state-of-the-art electrodes. This ANR value is ~30% lower than the charge transfer resistance of the same electrode composition in the absence of Fe2O3 nanoparticles. Detailed study of the Fe2O3 electrocatalytic properties reveals a significant improvement in the electrode's activity and performance stability with the addition of iron ions to the platinum-decorated oxidized graphene cathodes, indicating that these hybrid (Fe2O3|Graphene|Platinum) materials may serve as highly efficient catalysts for solid acid fuel cells and beyond. [ABSTRACT FROM AUTHOR]

The high cost and poor reliability of cathodic electrocatalysts for the oxygen reduction reaction (ORR), which requires significant amounts of expensive and scarce platinum, obstructs the broad applications of proton exchange membrane fuel cells (PEMFCs). The principles of ORR and the reasons for the poor stability of Pt-based catalysts are reviewed. Moreover, this paper discusses and categorizes the strategies for enhancing the stability of Pt-based catalysts in fuel cells. More importantly, it highlights the recent progress of Pt-based stability toward ORR, including surface-doping, intermetallic structures, 1D/2D structures, rational design of support, etc. Finally, for atomic-level in-depth information on ORR catalysts in fuel cells, potential perspectives are suggested, such as large-scale preparation, advanced interpretation techniques, and advanced simulation. This review aims to provide valuable insights into the fundamental science and technical engineering for practical Pt-based ORR electrocatalysts in fuel cells. [ABSTRACT FROM AUTHOR]

The oxygen reduction reaction (ORR) is an important challenge in the development and large-scale distribution of energy conversion devices, especially low-temperature proton exchange membrane (PEM) fuel cells. In order to speed up the ORR kinetics and improve fuel cell performance, iron-doped calcium titanate (CTFO) is proposed as a cocatalyst. Fundamental physical and chemical characterizations by means of X-ray diffraction, infrared spectroscopy, and morphological and thermal analyses for the understanding of the functional features of the proposed materials were carried out. Composite catalysts containing different amounts of CTFO additive with respect to platinum (i.e., Pt:CTFO 1:0.5 and 1:1 wt:wt) were studied using a rotating disk electrode (RDE). Fuel cell tests were performed at 80 °C under 30% and 80% relative humidity. The best Pt:CTFO composite catalyst was compared to a bare Pt/C and a Pt/C:CaTiO3−δ 1:1 catalyst, revealing superior performances of the latter at high relative humidity fuel cell operation, as a combined result of an optimized electrolyte-electrode interface and improved ORR kinetics due to the inorganic additive. [ABSTRACT FROM AUTHOR]

Platinum–dysprosium (Pt–Dy) alloys prepared by the arc melting technique are assessed as potential electrodes for the oxygen reduction reaction (ORR) using voltammetry and chronoamperometry in alkaline media. A relatively small change (10 at.%) in the alloy composition brought a notable difference in the alloys' performance for the ORR. Pt40Dy60 electrode, i.e., the electrode with a lower amount of Pt, was identified to have a higher activity towards ORR as evidenced by lower overpotential and higher current densities under identical experimental conditions. Furthermore, DFT calculations point out the unique single-atom-like coordination and electronic structure of Pt atoms in the Pt40Dy60 surface as responsible for enhanced ORR activity compared to the alloy with a higher Pt content. Additionally, Pt–Dy alloys showed activity in the oxygen evolution reaction (OER), with the OER current density lower than that of pure Pt. [ABSTRACT FROM AUTHOR]

TiO2-based mixed oxide–carbon composite supports have been suggested to provide enhanced stability for platinum (Pt) electrocatalysts in polymer electrolyte membrane (PEM) fuel cells. The addition of molybdenum (Mo) to the mixed oxide is known to increase the CO tolerance of the electrocatalyst. In this work Pt catalysts, supported on Ti1−xMoxO2–C composites with a 25/75 oxide/carbon mass ratio and prepared from different carbon materials (C: Vulcan XC-72, unmodified and functionalized Black Pearls 2000), were compared in the hydrogen oxidation reaction (HOR) and in the oxygen reduction reaction (ORR) with a commercial Pt/C reference catalyst in order to assess the influence of the support on the electrocatalytic behavior. Our aim was to perform electrochemical studies in preparation for fuel cell tests. The ORR kinetic parameters from the Koutecky–Levich plot suggested a four-electron transfer per oxygen molecule, resulting in H2O. The similarity between the Tafel slopes suggested the same reaction mechanism for electrocatalysts supported by these composites. The HOR activity of the composite-supported electrocatalysts was independent of the type of carbonaceous material. A noticeable difference in the stability of the catalysts appeared only after 5000 polarization cycles; the Black Pearl-containing sample showed the highest stability. [ABSTRACT FROM AUTHOR]

Hydrogen evolution reaction (HER) and oxygen reduction reaction (ORR) are two core electrochemical processes involved in hydrogen fuel cell (HFC) technology. ORR is a cathodic reaction occurring in HFC, whereas HER can convert the H2O byproduct from HFCs into H2 gas via water splitting. Platinum (Pt)-based catalysts are the most effective catalysts for both reactions. In this work, we used a fast, facile, and chemical-free method, called solution plasma sputtering (SPS), to synthesize Pt nanoparticles supported on Ketjen Black (KB). The discharge time was varied (5, 10, and 20 min) to alter the Pt loading. Characterization results revealed that the plasma did not affect the morphology of KB, and the Pt loading on KB increased with increasing discharge time (5.5-17.9 wt%). Well-crystallized Pt nanoparticles, ~2-5nmin diameter, were obtained. Electrochemical measurements revealed that Pt/KB exhibited bifunctional catalytic activity toward HER and ORR in 0.5 M H2SO4 solution. Both HER and ORR activities enhanced as the loading of Pt nanoparticles increased with a longer discharge time. Moreover, Pt/KB exhibited better HER and ORR stability than a commercial Pt-based catalyst, which was attributed to the stronger adhesion between Pt nanoparticles and KB support. Thus, SPS can be applied as an alternative synthesis method for preparing Pt/KB catalysts for HER and ORR. [ABSTRACT FROM AUTHOR]

The oxygen reduction reaction (ORR) is the oldest studied and most challenging of the electrochemical reactions. Due to its sluggish kinetics, ORR became the major contemporary technological hurdle for electrochemists, as it hampers the commercialization of fuel cell (FC) technologies. Downsizing the metal particles to nanoscale introduces unexpected fundamental modifications compared to the corresponding bulk state. To address these fundamental issues, various synthetic routes have been developed in order to provide more versatile carbon-supported low platinum catalysts. Consequently, the approach of using nanocatalysts may overcome the drawbacks encountered in massive materials for energy conversion. This review paper aims at summarizing the recent important advances in carbon-supported metal nanoparticles preparation from colloidal methods (microemulsion, polyol, impregnation, Bromide Anion Exchange...) as cathode material in low temperature FCs. Special attention is devoted to the correlation of the structure of the nanoparticles and their catalytic properties. The influence of the synthesis method on the electrochemical properties of the resulting catalysts is also discussed. Emphasis on analyzing data from theoretical models to address the intrinsic and specific electrocatalytic properties, depending on the synthetic method, is incorporated throughout. The synthesis process-nanomaterials structure-catalytic activity relationships highlighted herein, provide ample new rational, convenient and straightforward strategies and guidelines toward more effective nanomaterials design for energy conversion. [ABSTRACT FROM AUTHOR]

It is important to develop cost-efficient electrocatalysts used in the oxygen reduction reaction (ORR) for widespread applications in fuel cells. Palladium (Pd) is a promising catalyst, due to its more abundant reserves and lower price than platinum (Pt), and doping an earth-abundant 3d-transition metal M into Pd to form Pd–M bimetallic alloys may not only further reduce the use of expensive Pd but also promote the electrocatalytic performance of ORR, owing to the synergistic effect between Pd and M. Here we report a cyanogel-derived synthesis of PdFe alloys with porous nanostructure via a simple coinstantaneous reduction reaction by using K2PdIICl4/K4FeII(CN)6 cyanogel as precursor. The synthesized PdFe alloys possess hydrangea-like morphology and porous nanostructure, which are beneficial to the electrochemical performance in ORR. The onset potential of the porous PdFe nanohydrangeas is determined to be 0.988 V, which is much more positive than that of commercial Pt/C catalyst (0.976 V) and Pd black catalyst (0.964 V). Resulting from the unique structural advantages and synergetic effect between bimetals, the synthesized PdFe nanohydrangeas with porous structure have outstanding electrocatalytic activity and stability for ORR, compared with the commercial Pd black and Pt/C. [ABSTRACT FROM AUTHOR]

The development of active hydrogen oxidation reaction (HOR) and oxygen reduction reaction (ORR) catalysts for use in anion exchange membrane fuel cells (AEMFCs), which are free from platinum group metals (PGMs), is expected to bring this technology one step closer to commercial applications. This paper reports our recent progress developing HOR Pt-free and PGM-free catalysts (Pd/CeO2 and NiCo/C, respectively), and ORR PGM-free Co3O4 for AEMFCs. The catalysts were prepared by different synthesis techniques and characterized by both physical-chemical and electrochemical methods. A hydrothermally synthesized Co3O4 + C composite ORR catalyst used in combination with Pt/C as HOR catalyst shows good H2/O2 AEMFC performance (peak power density of ~388 mW cm−2), while the same catalyst coupled with our flame spray pyrolysis synthesised Pd/CeO2 anode catalysts reaches peak power densities of ~309 mW cm−2. Changing the anode to nanostructured NiCo/C catalyst, the performance is significantly reduced. This study confirms previous conclusions, that is indeed possible to develop high performing AEMFCs free from Pt; however, the challenge to achieve completely PGM-free AEMFCs still remains. [ABSTRACT FROM AUTHOR]

Structurally ordered intermetallic structure is an efficient catalyst design strategy to significantly improve the catalytic performance of Pt alloy electrocatalysts for oxygen reduction reaction in fuel cells. However, a high structural ordering degree generally relies on high-temperature annealing, which results in detrimental catalyst particle sintering. Herein, we reveal that the incompatibility between high ordering degree and minimum particle sintering during thermal annealing can be resolved through rational development of structurally ordered Pt ternary alloys. Ordering transformation mediated by high-temperature annealing of three representative Pt ternary alloys (Pt–Fe–Co, Pt–Ni–Co and Pt–Fe–Ni) at a similar Pt composition was systematically studied. It was found that Fe can significantly promote the structural ordering due to a faster atomic diffusion, whereas Co can effectively inhibit the particle sintering. As a result of the synergy between Co and Fe, the ordered PtCoFe catalyst exhibited the highest ordering degree after thermal annealing at 600 °C with the minimum nanoparticle growth, leading to the highest catalytic activity (0.65 A/mgPt at 0.9 V, 4 times that of pure Pt catalyst) and best stability (16% drop after 10,000 potential cycles). This study provides important clues for the rational design of high-performance structurally ordered ternary Pt alloys. [ABSTRACT FROM AUTHOR]

Developing the optimized electrocatalysts with high Pt utilization as well as the outstanding performance for the oxygen reduction reaction (ORR) has raised great attention. Herein, the effects of the interlayer ZrC, HfC, or TiN and the multilayer Pt shell on the adsorption ability and the catalytic activity of the TiC@Pt core-shell structures are systemically investigated by density functional theory (DFT) calculations. For the sandwich structures, the presence of TiN significantly enhances the adsorption ability of the Pt shell, leading to the deterioration of the activity whilst the negligible influence of the ZrC and HfC insertion results the comparable performance with respect to TiC@Pt1ML. In addition, increasing the thickness of the Pt shell reduces the oxyphilic capacity and then mitigates the OH poisoning. From the free energy plots, the superior activity of TiC@Pt2ML is identified in comparison with 1ML and 3ML Pt shell. Herein, the improved activity with its high Pt atomic utilization makes the potential TiC@Pt2ML electrocatalyst for the future fuel cells. [ABSTRACT FROM AUTHOR]