Remarkable Improvement of the Catalytic Performance of PtFe Nanoparticles by Structural Ordering and Doping

Highly stable and active catalyst in fuel cells through surface atomic ordering

Shape-controlled alloy nanoparticle catalysts have been shown to exhibit improved performance in the oxygen reduction reaction (ORR) in liquid half-cells. However, translating the success to catalyst layers in fuel cells faces challenges due to the more demanding operation conditions in membrane electrode assembly (MEA). Balancing durability and activity is crucial. Here, we developed a strategy that limits the atomic diffusion within surface layers, fostering the phase transition and shape retention during thermal treatment. This enables selective transformation of platinum-iron nanowire surfaces into intermetallic structures via atomic ordering at a low temperature. The catalysts exhibit enhanced MEA stability with 50% less Fe loss while maintaining high catalytic activity comparable to that in half-cells. Density functional calculations suggest that the ordered intermetallic surface stabilizes morphology against rapid corrosion and improves the ORR activity. The surface engineering through atomic ordering presents potential for practical application in fuel cells with shape-controlled Pt-based alloy catalysts.

Redesign of Anode Catalyst for Sustainable Survival of Fuel Cells

Polymer electrolyte membrane fuel cells (PEMFCs) suffer from severe performance degradation when operating under harsh conditions such as fuel starvation, shut-down/start-up, and open circuit voltage. A fundamental solution to these technical issues requires an integrated approach rather than condition-specific solutions. In this study, an anode catalyst based on Pt nanoparticles encapsulated in a multifunctional carbon layer (MCL), acting as a molecular sieve layer and protective layer is designed. The MCL enabled selective hydrogen oxidation reaction on the surface of the Pt nanoparticles while preventing their dissolution and agglomeration. Thus, the structural deterioration of a membrane electrode assembly can be effectively suppressed under various harsh operating conditions. The results demonstrated that redesigning the anode catalyst structure can serve as a promising strategy to maximize the service life of the current PEMFC system.

Intermetallic Nanocrystals for Fuel-Cells-Based Electrocatalysis

Electrocatalysis underpins the renewable electrochemical conversions for sustainability, which further replies on metallic nanocrystals as vital electrocatalysts. Intermetallic nanocrystals have been known to show distinct properties compared to their disordered counterparts, and been long explored for functional improvements. Tremendous progresses have been made in the past few years, with notable trend of more precise engineering down to an atomic level and the investigation transferring into more practical membrane electrode assembly (MEA), which motivates this timely review. After addressing the basic thermodynamic and kinetic fundamentals, we discuss classic and latest synthetic strategies that enable not only the formation of intermetallic phase but also the rational control of other catalysis-determinant structural parameters, such as size and morphology. We also demonstrate the emerging intermetallic nanomaterials for potentially further advancement in energy electrocatalysis. Then, we discuss the state-of-the-art characterizations and representative intermetallic electrocatalysts with emphasis on oxygen reduction reaction evaluated in a MEA setup. We summarize this review by laying out existing challenges and offering perspective on future research directions toward practicing intermetallic electrocatalysts for energy conversions.

Pt-Based Oxygen Reduction Reaction Catalysts in Proton Exchange Membrane Fuel Cells: Controllable Preparation and Structural Design of Catalytic Layer

Proton exchange membrane fuel cells (PEMFCs) have attracted extensive attention because of their high efficiency, environmental friendliness, and lack of noise pollution. However, PEMFCs still face many difficulties in practical application, such as insufficient power density, high cost, and poor durability. The main reason for these difficulties is the slow oxygen reduction reaction (ORR) on the cathode due to the insufficient stability and catalytic activity of the catalyst. Therefore, it is very important to develop advanced platinum (Pt)-based catalysts to realize low Pt loads and long-term operation of membrane electrode assembly (MEA) modules to improve the performance of PEMFC. At present, the research on PEMFC has mainly been focused on two areas: Pt-based catalysts and the structural design of catalytic layers. This review focused on the latest research progress of the controllable preparation of Pt-based ORR catalysts and structural design of catalytic layers in PEMFC. Firstly, the design principle of advanced Pt-based catalysts was introduced. Secondly, the controllable preparation of catalyst structure, morphology, composition and support, and their influence on catalytic activity of ORR and overall performance of PEMFC, were discussed. Thirdly, the effects of optimizing the structure of the catalytic layer (CL) on the performance of MEA were analyzed. Finally, the challenges and prospects of Pt-based catalysts and catalytic layer design were discussed.

Ordered intermetallic compounds combining precious metals and transition metals for electrocatalysis

Ordered intermetallic alloys with significantly improved activity and stability have attracted extensive attention as advanced electrocatalysts for reactions in polymer electrolyte membrane fuel cells (PEMFCs). Here, recent advances in tuning intermetallic Pt- and Pd-based nanocrystals with tunable morphology and structure in PEMFCs to catalyze the cathodic reduction of oxygen and the anodic oxidation of fuels are highlighted. The fabrication/tuning of ordered noble metal-transition metal-bonded intermetallic PtM and PdM (M = Fe, Co) nanocrystals by using high temperature annealing treatments to promote the activity and stability of electrocatalytic reactions are discussed. Furthermore, the further improvement of the efficiency of this unique ordered intermetallic alloys for electrocatalysis are also proposed and discussed. This report aims to demonstrate the potential of the ordered intermetallic strategy of noble and transition metals to facilitate electrocatalysis and facilitate more research efforts in this field.

Operating interfaces to synthesize L10-FePt@Bi-rich nanoparticles by modifying the heating process

A facile strategy to operate interfaces when synthesizing L1₀-FePt@Bi-rich nanoparticles (NPs) has been proposed. Two interfaces are indispensable to obtain the high ordering L1₀-FePt structure. One is the mismatched interfaces between the initial γ-PtBi₂ nuclei and the disordered fcc-FePt phase. The other is the in situ grown coherent interfaces between the L1₀-FePt and Bi-rich phases. Increasing the heating rates when the temperature rises from 120 °C to 310 °C benefits the formation of mismatched interfaces and improves the uniformity of phases and composition in NPs. Reducing the heating rate at higher temperature ensures sufficient time for Bi to diffuse across the coherent interface, which facilitates the disorder-order transition of L1₀-FePt NPs. This study provides a new perspective on operating interfaces during the wet-chemical synthesis process.

Recent progress of electrocatalysts for oxygen reduction in fuel cells

Oxygen reduction reaction (ORR) has gradually been in the limelight in recent years because of its great application potential for fuel cells and rechargeable metal-air batteries. Therefore, significant issues are increasingly focused on developing effective and economical ORR electrocatalysts. This review begins with the reaction mechanisms and theoretical calculations of ORR in acidic and alkaline media. The latest reports and challenges in ORR electrocatalysis are traced. Most importantly, the latest advances in the development of ORR electrocatalysts are presented in detail, including platinum group metal (PGM), transition metal, and carbon-based electrocatalysts with various nanostructures. Furthermore, the development prospects and challenges of ORR electrocatalysts are speculated and discussed. These insights would help to formulate the design guidelines for highly-active ORR electrocatalysts and affect future research to obtain new knowledge for ORR mechanisms.

Pt-Based Intermetallic Nanocrystals in Cathode Catalysts for Proton Exchange Membrane Fuel Cells: From Precise Synthesis to Oxygen Reduction Reaction Strategy

Although oxygen reduction reaction (ORR) catalysts have been extensively investigated and developed, there is a lack of clarity on catalysts that can balance high performance and low cost. Pt-based intermetallic nanocrystals are of special interest in the commercialization of proton exchange membrane fuel cells (PEMFCs) due to their excellent ORR activity and stability. This review summarizes the wide range of applications of Pt-based intermetallic nanocrystals in cathode catalysts for PEMFCs and their unique advantages in the field of ORR. Firstly, we introduce the fundamental understanding of Pt-based intermetallic nanocrystals, and highlight the difficulties and countermeasures in their synthesis. Then, the progress of theoretical and experimental studies related to the ORR activity and stability of Pt-based intermetallic nanocrystals in recent years are reviewed, especially the integrated strategies for enhancing the stability of ORR. Finally, the challenges faced by Pt-based intermetallic nanocrystals are summarized and future research directions are proposed. In addition, numerous design ideas of Pt-based intermetallic nanocrystals as ORR catalysts are summarized, aiming to promote further development of commercialization of PEMFC catalysts while fully understanding Pt-based intermetallic nanocrystals.

Magnetism and Heterogeneous Catalysis: In Depth on the Quantum Spin-Exchange Interactions in Pt3M (M = V, Cr, Mn, Fe, Co, Ni, and Y)(111) Alloys

Bimetallic Pt-based alloys have drawn considerable attention in the last decades as catalysts in proton-exchange membrane fuel cells (PEMFCs) because they closely fulfill the two major requirements of high performance and good stability under operating conditions. Pt₃Fe, Pt₃Co, and Pt₃Ni stand out as major candidates, given their good activity toward the challenging oxygen reduction reaction (ORR). The common feature across catalysts based on 3d-transition metals and their alloys is magnetism. Ferromagnetic spin-electron interactions, quantum spin-exchange interactions (QSEIs), are one of the most important energetic contributions in allowing milder chemisorption of reactants onto magnetic catalysts, in addition to spin-selective electron transport. The understanding of the role played by QSEIs in the properties of magnetic 3d-metal-based alloys is important to design and develop novel and effective electrocatalysts based on abundant and cheap metals. We present a detailed theoretical study (via density functional theory) on the most experimentally explored bimetallic alloys Pt₃M (M = V, Cr, Mn, Fe, Co, Ni, and Y)(111). The investigation starts with a thorough structural study on the composition of the layers, followed by a comprehensive physicochemical description of their resistance toward segregation and their chemisorption capabilities toward hydrogen and oxygen atoms. Our study demonstrates that Pt₃Fe(111), Pt₃Co(111), and Pt₃Ni(111) possess the same preferential multilayered structural organization, known for exhibiting specific magnetic properties. The specific role of QSEIs in their catalytic behavior is justified via comparison between spin-polarized and non-spin-polarized calculations.

Electrospinning Synthesis of Carbon-Supported Pt3Mn Intermetallic Nanocrystals and Electrocatalytic Performance towards Oxygen Reduction Reaction

To realize the large-scale application of fuel cells, it is still a great challenge to improve the performance and reduce the cost of cathode catalysts towards oxygen reduction reaction (ORR). In this work, carbon-supported ordered Pt₃Mn intermetallic catalysts were prepared by thermal annealing electrospun polyacrylonitrile nanofibers containing Platinum(II) acetylacetonate/ Manganese(III) acetylacetonate. Compared with its counterparts, the ordered Pt₃Mn intermetallic obtained at 950 °C exhibits a more positive half-potential and higher kinetic current density during the ORR process. Benefiting from their defined stoichiometry and crystal structure, the Mn atoms in Pt₃Mn intermetallic can modulate well the geometric and electronic structure of surface Pt atoms, endowing Pt₃Mn catalyst with an enhanced ORR catalytic activity. Moreover, it also has a better catalytic stability and methanol tolerance than commercial Pt/C catalyst. Our study provides a new strategy to fabricate a highly active and durable Pt₃Mn intermetallic electrocatalyst towards ORR.