Size and Composition Dependence of Oxygen Reduction Reaction Catalytic Activities of Mo-Doped PtNi/C Octahedral Nanocrystals

Surface engineering for stable electrocatalysis

In recent decades, significant progress has been achieved in rational developments of electrocatalysts through constructing novel atomistic structures and modulating catalytic surface topography, realizing substantial enhancement in electrocatalytic activities. Numerous advanced catalysts were developed for electrochemical energy conversion, exhibiting low overpotential, high intrinsic activity, and selectivity. Yet, maintaining the high catalytic performance under working conditions with high polarization and vigorous microkinetics that induce intensive degradation of surface nanostructures presents a significant challenge for commercial applications. Recently, advanced operando and computational techniques have provided comprehensive mechanistic insights into the degradation of surficial functional structures. Additionally, various innovative strategies have been devised and proven effective in sustaining electrocatalytic activity under harsh operating conditions. This review aims to discuss the most recent understanding of the degradation microkinetics of catalysts across an entire range of anodic to cathodic polarizations, encompassing processes such as oxygen evolution and reduction, hydrogen reduction, and carbon dioxide reduction. Subsequently, innovative strategies adopted to stabilize the materials' structure and activity are highlighted with an in-depth discussion of the underlying rationale. Finally, we present conclusions and perspectives regarding future research and development. By identifying the research gaps, this review aims to inspire further exploration of surface degradation mechanisms and rational design of durable electrocatalysts, ultimately contributing to the large-scale utilization of electroconversion technologies.

Stability of high-entropy alloys under electrocatalytic conditions

High-entropy alloys are claimed to possess superior stability due to thermodynamic contributions. However, this statement mostly lies on a hypothetical basis. In this study, we use on-line inductively coupled plasma mass spectrometer to investigate the dissolution of five representative electrocatalysts in acidic and alkaline media and a wide potential window targeting the most important applications. To address both model and applied systems, we synthesized thin films and carbon-supported nanoparticles ranging from an elemental (Pt) sample to binary (PtRu), ternary (PtRuIr), quaternary (PtRuIrRh), and quinary (PtRuIrRhPd) alloy samples. For certain metals in the high-entropy alloy under alkaline conditions, lower dissolution was observed. Still, the improvement was not striking and can be rather explained by the lowered concentration of elements in the multinary alloys instead of the synergistic effects of thermodynamics. We postulate that this is because of dissolution kinetic effects, which are always present under electrocatalytic conditions, overcompensating thermodynamic contributions.

Bimetallic Nanoalloy Catalysts for Green Energy Production: Advances in Synthesis Routes and Characterization Techniques

Bimetallic Nanoalloy catalysts have diverse uses in clean energy, sensing, catalysis, biomedicine, and energy storage, with some supported and unsupported catalysts. Conventional synthetic methods for producing bimetallic alloy nanoparticles often produce unalloyed and bulky particles that do not exhibit desired characteristics. Alloys, when prepared with advanced nanoscale methods, give higher surface area, activity, and selectivity than individual metals due to changes in their electronic properties and reduced size. This review demonstrates the synthesis methods and principles to produce and characterize highly dispersed, well-alloyed bimetallic nanoalloy particles in relatively simple, effective, and generalized approaches and the overall existence of conventional synthetic methods with modifications to prepare bimetallic alloy catalysts. The basic concepts and mechanistic understanding are represented with purposely selected examples. Herein, the enthralling properties with widespread applications of nanoalloy catalysts in heterogeneous catalysis are also presented, especially for Hydrogen Evolution Reaction (HER), Oxidation Reduction Reaction (ORR), Oxygen Evolution Reaction (OER), and alcohol oxidation with a particular focus on Pt and Pd-based bimetallic nanoalloys and their numerous fields of applications. The high entropy alloy is described as a complicated subject with an emphasis on laser-based green synthesis of nanoparticles and, in conclusion, the forecasts and contemporary challenges for the controlled synthesis of nanoalloys are addressed.

In Situ Structure of a Mo-Doped Pt-Ni Catalyst during Electrochemical Oxygen Reduction Resolved from Machine Learning-Based Grand Canonical Global Optimization

Pt-Ni alloy is by far the most active cathode material for oxygen reduction reaction (ORR) in the proton-exchange membrane fuel cell, and the addition of a tiny amount of a third-metal Mo can significantly improve the catalyst durability and activity. Here, by developing machine learning-based grand canonical global optimization, we are able to resolve the in situ structures of this important three-element alloy system under ORR conditions and identify their correlations with the enhanced ORR performance. We disclose the bulk phase diagram of Pt-Ni-Mo alloys and determine the surface structures under the ORR reaction conditions by exploring millions of likely structure candidates. The pristine Pt-Ni-Mo alloy surfaces are shown to undergo significant structure reconstruction under ORR reaction conditions, where a surface-adsorbed MoO₄ monomer or Mo₂O _x dimers cover the Pt-skin surface above 0.9 V vs RHE and protect the surface from Ni leaching. The physical origins are revealed by analyzing the electronic structure of O atoms in MoO₄ and on the Pt surface. In viewing the role of high-valence transition metal oxide clusters, we propose a set of quantitative measures for designing better catalysts and predict that six elements in the periodic table, namely, Mo, Tc, Os, Ta, Re, and W, can be good candidates for alloying with PtNi to improve the ORR catalytic performance. We demonstrate that machine learning-based grand canonical global optimization is a powerful and generic tool to reveal the catalyst dynamics behavior in contact with a complex reaction environment.

Unique (100) Surface Configuration Enables Promising Oxygen Reduction Performance for Pt3Co Nanodendrite Catalysts

Selective exposure of active surfaces of Pt-based electrocatalysts has been demonstrated as an effective strategy to improve Pt utilization and promote oxygen reduction reaction (ORR) activity in fuel cell application. However, challenges remain in stabilizing those active surface structures, which often suffer undesirable degradation and poor durability along with surface passivation, metal dissolution, and agglomeration of Pt-based electrocatalysts. To overcome the aforementioned obstacles, we here demonstrate the unique (100) surface configuration enabling active and stable ORR performance for bimetallic Pt₃Co nanodendrite structures. Using elaborate microscopy and spectroscopy characterization, it is revealed that the Co atoms are preferentially segregated and oxidized at the Pt₃Co(100) surface. In situ X-ray absorption spectroscopy (XAS) shows that such (100) surface configuration prevents the oxygen chemisorption and oxide formation on active Pt during the ORR process. Thus, the Pt₃Co nanodendrite catalyst shows not only a high ORR mass activity of 730 mA/mg at 0.9 V vs RHE, which is 6.6-fold higher than that of the Pt/C, but also impressively high stability with 98% current retention after the acceleration degradation test in acid media for 5000 cycles, far exceeding the Pt or Pt₃Co nanoparticles. Density functional theory (DFT) calculation also confirms the lateral and structural effects from the segregated Co and oxides on the Pt₃Co(100) surface in reducing the catalyst oxophilicity and the free energy for the formation of an OH intermediate in the ORR.

Catalytic Activity Maps for Alloy Nanoparticles

To enable rational design of alloy nanoparticle catalysts, we develop an approach to generate catalytic activity maps of alloy nanoparticles on a grid of particle size and composition. The catalytic activity maps are created by using a quaternary cluster expansion to explicitly predict adsorbate binding energies on alloy nanoparticles of varying shape, size, and atomic order while accounting for interactions among the adsorbates. This cluster expansion is used in kinetic Monte Carlo simulations to predict activated nanoparticle structures and turnover frequencies on all surface sites. We demonstrate our approach on Pt-Ni octahedral nanoparticle catalysts for the oxygen reduction reaction (ORR), revealing that the specific activity is predicted to be optimized at an edge length of larger than 5.5 nm and a composition of about Pt_0.85Ni_0.15 and the mass activity is predicted to be optimized at an edge length of 3.3-3.8 nm and a composition of about Pt_0.8Ni_0.2.

Stabilization of a Mn-Co Oxide During Oxygen Evolution in Alkaline Media

Improving the stability of electrocatalysts for the oxygen evolution reaction (OER) through materials design has received less attention than improving their catalytic activity. We explored the effects of Mn addition to a cobalt oxide for stabilizing the catalyst by comparing single phase CoOx and (Co0.7Mn0.3)Ox films electrodeposited in alkaline solution. The obtained disordered films were classified as layered oxides using X-ray absorption spectroscopy (XAS). The CoOx films showed a constant decrease in the catalytic activity during cycling, confirmed by oxygen detection, while that of (Co0.7Mn0.3)Ox remained constant within error as measured by electrochemical metrics. These trends were rationalized based on XAS analysis of the metal oxidation states, which were Co2.7+ and Mn3.7+ in the bulk and similar near the surface of (Co0.7Mn0.3)Ox, before and after cycling. Thus, Mn in (Co0.7Mn0.3)Ox successfully stabilized the bulk catalyst material and its surface activity during OER cycling. The development of stabilization approaches is essential to extend the durability of OER catalysts.

Highly Active and Stable Large Mo-Doped Pt-Ni Octahedral Catalysts for ORR: Synthesis, Post-treatments, and Electrochemical Performance and Stability

Over the past decade, advances in the colloidal syntheses of octahedral-shaped Pt-Ni alloy nanocatalysts for use in fuel cell cathodes have raised our atomic-scale control of particle morphology and surface composition, which, in turn, helped raise their catalytic activity far above that of benchmark Pt catalysts. Future fuel cell deployment in heavy-duty vehicles caused the scientific priorities to shift from alloy particle activity to stability. Larger particles generally offer enhanced thermodynamic stability, yet synthetic approaches toward larger octahedral Pt-Ni alloy nanoparticles have remained elusive. In this study, we show how a simple manipulation of solvothermal synthesis reaction kinetics involving depressurization of the gas phase at different stages of the reaction allows tuning the size of the resulting octahedral nanocatalysts to previously unachieved scales. We then link the underlying mechanism of our approach to the classical "LaMer" model of nucleation and growth. We focus on large, annealed Mo-doped Pt-Ni octahedra and investigate their synthesis, post-synthesis treatments, and elemental distribution using advanced electron microscopy. We evaluate the electrocatalytic ORR performance and stability and succeed to obtain a deeper understanding of the enhanced stability of a new class of relatively large, active, and long-lived Mo-doped Pt-Ni octahedral catalysts for the cathode of PEMFCs.

Gram-Scale Synthesis of Carbon-Supported Sub-5 nm PtNi Nanocrystals for Efficient Oxygen Reduction

The preparation of a high performance and durability with low-platinum (Pt) loading oxygen reduction catalysts remains a challenge for the practical application of fuel cells. Alloying Pt with a transition metal can greatly improve the activity and durability for oxygen reduction reaction (ORR). In this work, we present a one-pot wet-chemical strategy to controllably synthesize carbon supported sub-5 nm PtNi nanocrystals with a ~3% Pt loading. The as-prepared PtNi/C-200 catalyst with a Pt/Ni atomic ratio of 2:3 shows a high oxygen reduction activity of 0.66 A mgpt−1 and outstanding durability over 10,000 potential cycles in 0.1 M KOH in a half-cell condition. The PtNi/C-200 catalyst exhibits the highest ORR activity, with an onset potential (Eonset) of 0.98 V and a half-wave potential (E1/2) of 0.84 V. The mass activity and specific activity are 3.89 times and 9.16 times those of 5% commercial Pt/C. More importantly, this strategy can be applied to the gram-scale synthesis of high-efficiency electrocatalysts. As a result, this effective synthesis strategy has a significant meaning in practical applications of full cells.

Seed-Mediated, Shape-Controlled Synthesis Methods for Platinum-Based Electrocatalysts for the Oxygen Reduction Reaction—A Mini Review

Overcoming the slow oxygen reduction reaction (ORR) kinetics at the cathode of the hydrogen fuel cells requires the use of electrocatalysts containing expensive and scare platinum to achieve reasonable performance, hampering widespread use of the technology due to high material costs and sustainability issues. One option available to tackle this issue is to use new designs to create nanomaterials which achieve excellent electrocatalytic performances and long-lasting stabilities whilst using less platinum than is currently required. Reliably producing nanomaterials with predictable activities and stabilities using simple, safe, and scalable methods is an important research topic to the advancement of fuel cell technologies. The oxygen reduction reaction occurs at the surface of electrocatalytic materials, and since nanomaterial structures exhibit different catalytic activities, their shapes have a strong relationship to the final performance. Seed-mediated synthesis can be used to control the shape of materials with the aim of obtaining products with the most desirable surface properties for the ORR. This review summarized the current advancement of the synthesis of platinum-based ORR and provided the insights for the future development of this field.

On the electrocatalytical oxygen reduction reaction activity and stability of quaternary RhMo-doped PtNi/C octahedral nanocrystals

Recently proposed bimetallic octahedral Pt–Ni electrocatalysts for the oxygen reduction reaction (ORR) in proton exchange membrane fuel cell (PEMFC) cathodes suffer from particle instabilities in the form of Ni corrosion and shape degradation. Advanced trimetallic Pt-based electrocatalysts have contributed to their catalytic performance and stability. In this work, we propose and analyse a novel quaternary octahedral (oh-)Pt nanoalloy concept with two distinct metals serving as stabilizing surface dopants. An efficient solvothermal one-pot strategy was developed for the preparation of shape-controlled oh-PtNi catalysts doped with Rh and Mo in its surface. The as-prepared quaternary octahedral PtNi(RhMo) catalysts showed exceptionally high ORR performance accompanied by improved activity and shape integrity after stability tests compared to previously reported bi- and tri-metallic systems. Synthesis, performance characteristics and degradation behaviour are investigated targeting deeper understanding for catalyst system improvement strategies. A number of different operando and on-line analysis techniques were employed to monitor the structural and elemental evolution, including identical location scanning transmission electron microscopy and energy dispersive X-ray analysis (IL-STEM-EDX), operando wide angle X-ray spectroscopy (WAXS), and on-line scanning flow cell inductively coupled plasma mass spectrometry (SFC-ICP-MS). Our studies show that doping PtNi octahedral catalysts with small amounts of Rh and Mo suppresses detrimental Pt diffusion and thus offers an attractive new family of shaped Pt alloy catalysts for deployment in PEMFC cathode layers.

PtNi nano-octahedra with Rh and Mo dopants are highly active catalysts for the oxygen reduction reaction with excellent stability and shape integrity. We investigate the morphological, structural, and compositional evolution during stability testing.