Karren L. More

High-Performance Electrocatalysts for Oxygen Reduction Derived from Polyaniline, Iron, and Cobalt

Fuel cell catalysts synthesized from abundant metals approach the performance and durability of platinum at lower cost. The prohibitive cost of platinum for catalyzing the cathodic oxygen reduction reaction (ORR) has hampered the widespread use of polymer electrolyte fuel cells. We describe a family of non–precious metal catalysts that approach the performance of platinum-based systems at a cost sustainable for high-power fuel cell applications, possibly including automotive power. The approach uses polyaniline as a precursor to a carbon-nitrogen template for high-temperature synthesis of catalysts incorporating iron and cobalt. The most active materials in the group catalyze the ORR at potentials within ~60 millivolts of that delivered by state-of-the-art carbon-supported platinum, combining their high activity with remarkable performance stability for non–precious metal catalysts (700 hours at a fuel cell voltage of 0.4 volts) as well as excellent four-electron selectivity (hydrogen peroxide yield <1.0%).

Highly Crystalline Multimetallic Nanoframes with Three-Dimensional Electrocatalytic Surfaces

Giving Electrocatalysts an Edge Platinum (Pt) is an excellent catalyst for the oxygen-reduction reaction (ORR) in fuel cells and electrolyzers, but it is too expensive and scarce for widespread deployment, even when dispersed as Pt nanoparticles on carbon electrode supports (Pt/C). Alternatively, Chen et al. (p. 1339, published online 27 February; see the Perspective by Greer) made highly active ORR catalysts by dissolving away the interior of rhombic dodecahedral PtNi3 nanocrystals to leave Pt-rich Pt3Ni edges. These nanoframe catalysts are durable—remaining active after 10,000 rounds of voltage cycling—and are far more active than Pt/C. Highly active electrocatalysts are created by eroding away all but the edges of platinum-nickel nanocrystals. [Also see Perspective by Greer] Control of structure at the atomic level can precisely and effectively tune catalytic properties of materials, enabling enhancement in both activity and durability. We synthesized a highly active and durable class of electrocatalysts by exploiting the structural evolution of platinum-nickel (Pt-Ni) bimetallic nanocrystals. The starting material, crystalline PtNi3 polyhedra, transforms in solution by interior erosion into Pt3Ni nanoframes with surfaces that offer three-dimensional molecular accessibility. The edges of the Pt-rich PtNi3 polyhedra are maintained in the final Pt3Ni nanoframes. Both the interior and exterior catalytic surfaces of this open-framework structure are composed of the nanosegregated Pt-skin structure, which exhibits enhanced oxygen reduction reaction (ORR) activity. The Pt3Ni nanoframe catalysts achieved a factor of 36 enhancement in mass activity and a factor of 22 enhancement in specific activity, respectively, for this reaction (relative to state-of-the-art platinum-carbon catalysts) during prolonged exposure to reaction conditions.

Design and synthesis of bimetallic electrocatalyst with multilayered Pt-skin surfaces.

Advancement in heterogeneous catalysis relies on the capability of altering material structures at the nanoscale, and that is particularly important for the development of highly active electrocatalysts with uncompromised durability. Here, we report the design and synthesis of a Pt-bimetallic catalyst with multilayered Pt-skin surface, which shows superior electrocatalytic performance for the oxygen reduction reaction (ORR). This novel structure was first established on thin film extended surfaces with tailored composition profiles and then implemented in nanocatalysts by organic solution synthesis. Electrochemical studies for the ORR demonstrated that after prolonged exposure to reaction conditions, the Pt-bimetallic catalyst with multilayered Pt-skin surface exhibited an improvement factor of more than 1 order of magnitude in activity versus conventional Pt catalysts. The substantially enhanced catalytic activity and durability indicate great potential for improving the material properties by fine-tuning of the nanoscale architecture.

Multimetallic Au/FePt3 Nanoparticles as Highly Durable Electrocatalyst

We report the design and synthesis of multimetallic Au/Pt-bimetallic nanoparticles as a highly durable electrocatalyst for the oxygen reduction reaction (ORR) in proton exchange membrane fuel cells. This system was first studied on well-defined Pt and FePt thin films deposited on a Au(111) surface, which has guided the development of novel synthetic routes toward shape-controlled Au nanoparticles coated with a Pt-bimetallic alloy. It has been demonstrated that these multimetallic Au/FePt(3) nanoparticles possess both the high catalytic activity of Pt-bimetallic alloys and the superior durability of the tailored morphology and composition profile, with mass-activity enhancement of more than 1 order of magnitude over Pt catalysts. The reported synergy between well-defined surfaces and nanoparticle synthesis offers a persuasive approach toward advanced functional nanomaterials.

Synthesis-structure-performance correlation for polyaniline-Me-C non-precious metal cathode catalysts for oxygen reduction in fuel cells

In this report, we present the systematic preparation of active and durable non-precious metal catalysts (NPMCs) for the oxygen reduction reaction in polymer electrolyte fuel cells (PEFCs) based on the heat treatment of polyaniline/metal/carbon precursors. Variation of the synthesis steps, heat-treatment temperature, metal loading, and the metal type in the synthesis leads to markedly different catalyst activity, speciation, and morphology. Microscopy studies demonstrate notable differences in the carbon structure as a function of these variables. Balancing the need to increase the catalyst’s degree of graphitization through heat treatment versus the excessive loss of surface area that occurs at higher temperatures is a key to preparing an active catalyst. XPS and XAFS spectra are consistent with the presence of Me–Nx structures in both the Co and Fe versions of the catalyst, which are often proposed to be active sites. The average speciation and coordination environment of nitrogen and metal, however, depends greatly on the choice of Co or Fe. Taken together, the data indicate that better control of the metal-catalyzed transformations of the polymer into new graphitized carbon forms in the heat-treatment step will allow for even further improvement of this class of catalysts.

Core/Shell Pd/FePt Nanoparticles as an Active and Durable Catalyst for the Oxygen Reduction Reaction

We report a unique synthesis of core/shell Pd/FePt nanoparticles (NPs) and their catalysis of the oxygen reduction reaction (ORR). The uniform FePt shell is formed by controlled nucleation of Fe(CO)(5) in the presence of a Pt salt and Pd NPs at designated reaction temperatures. The Pd/FePt NPs show FePt shell-dependent catalytic properties, and those having a 1 nm FePt shell exhibit a drastic increase in durability and activity (15 times more active with a 140 mV gain in onset potential in comparison with those having a 3 nm coating). These Pd/FePt NPs are promising new catalysts for practical fuel cell applications.

Microstructural Changes of Membrane Electrode Assemblies during PEFC Durability Testing at High Humidity Conditions

Morphological changes occurring in membrane electrode assemblies (MEAs) were monitored using transmission electron microscopy (TEM) during the course of life testing of H 2 /air polymer electrolyte fuel cells (PEFCs). In the fresh catalyst layers, anode Pt particles were found to have smaller particle sizes, better dispersion, and less agglomeration on the carbon-support surfaces than did the cathode Pt 3 Cr alloy particles. The operation-induced agglomeration of catalyst particles was evaluated for both the anode and cathode after defined life testing periods. Agglomeration of catalyst particles occurred primarily during the first 500 h of testing, which was confirmed by both TEM analysis and electrocatalytic surface area measurement. After 500 h, degradation of the recast Nafion ionomer network within the catalyst layers likely contributes more significantly to MEA performance degradation. Migration of metal catalyst particles toward the interface between the catalyst layer and membrane was observed at both electrodes. The Pt anode catalyst was less stable than the Pt 3 Cr cathode catalyst under high current density and high humidity conditions, which was confirmed by the higher extent of migration observed for the pure Pt than for the Pt 3 Cr. Some Pt particles (from both electrodes) were found to migrate into the membrane during the testing period.

Phase evolution in boron nitride thin films

Boron nitride (BN) thin films were deposited on monocrystalline Si (100) wafers using electron beam evaporation of boron with simultaneous bombardment by nitrogen and argon ions. The effect of film thickness on the resultant BN phase was investigated using Fourier transform infrared (FTIR) spectroscopy and high resolution transmission electron microscopy (HRTEM). These techniques revealed the consecutive deposition of an initial 20 A thick layer of amorphous BN, 20--50 A of hexagonal BN having a layered structure, and a final layer of the cubic phase. The growth sequence of the layers is believed to result primarily from increasing biaxial compressive stresses. Favorable surface and interface energy and crystallographic relationships may also assist in the nucleation of the cubic and the hexagonal phases, respectively. The presence of the amorphous and hexagonal regions explains why there have been no reports of the growth of 100% cubic boron nitride on Si.

A Facile Synthesis of MPd (M = Co, Cu) Nanoparticles and Their Catalysis for Formic Acid Oxidation

Monodisperse CoPd nanoparticles (NPs) were synthesized and studied for catalytic formic acid (HCOOH) oxidation (FAO). The NPs were prepared by coreduction of Co(acac)(2) (acac = acetylacetonate) and PdBr(2) at 260 °C in oleylamine and trioctylphosphine, and their sizes (5-12 nm) and compositions (Co(10)Pd(90) to Co(60)Pd(40)) were controlled by heating ramp rate, metal salt concentration, or metal molar ratios. The 8 nm CoPd NPs were activated for HCOOH oxidation by a simple ethanol wash. In 0.1 M HClO(4) and 2 M HCOOH solution, their catalytic activities followed the trend of Co(50)Pd(50) > Co(60)Pd(40) > Co(10)Pd(90) > Pd. The Co(50)Pd(50) NPs had an oxidation peak at 0.4 V with a peak current density of 774 A/g(Pd). As a comparison, commercial Pd catalysts showed an oxidation peak at 0.75 V with peak current density of only 254 A/g(Pd). The synthesis procedure could also be extended to prepare CuPd NPs when Co(acac)(2) was replaced by Cu(ac)(2) (ac = acetate) in an otherwise identical condition. The CuPd NPs were less active catalysts than CoPd or even Pd for FAO in HClO(4) solution. The synthesis provides a general approach to Pd-based bimetallic NPs and will enable further investigation of Pd-based alloy NPs for electro-oxidation and other catalytic reactions.

A carbon-nanotube-supported graphene-rich non-precious metal oxygen reduction catalyst with enhanced performance durability

A non-precious metal catalyst for oxygen reduction in acid media, enriched in graphene sheets/bubbles during a high-temperature synthesis step, has been developed from an Fe precursor and in situ polymerized polyaniline, supported on multi-walled carbon nanotubes. The catalyst showed no performance loss for 500 hours in a hydrogen/air fuel cell. The improved durability is correlated with the graphene formation, apparently enhanced in the presence of carbon nanotubes.