Seed-Mediated Synthesis of High Loading PtCo Intermetallic Compounds Enhanced Catalytic Efficacy and Long-Term Stability for Oxygen Reduction Reaction.

Atomically ordered intermetallic Pt-based nanoparticles, recognized as advanced electrocatalysts, exhibit superior activity for the oxygen reduction reaction (ORR) in fuel cell cathodes. Nevertheless, the formation of these ordered structures typically necessitates elevated annealing temperatures, which can accelerate particle growth and diminished reactivity. In this study, we synthesized carbon-supported platinum-cobalt intermetallic compounds (PtCo-IMCs) with sub-4 nm particle sizes and uniform distribution. These catalysts, characterized by high platinum content and exceptional ORR activity, are specifically tailored for heavy-duty vehicle (HDV) applications. The PtCo-IMCs exhibited significantly enhanced catalytic performance and durability compared to conventional Pt-based catalysts, utilizing platinum nanoparticles as nucleation sites to promote growth. This method effectively retained smaller particle sizes while achieving a higher degree of ordering and alloying during high-temperature annealing. Optimization of the annealing temperature resulted in peak activity and stability at 800 °C. The mass activity (MA) of the PtCo-800 catalyst was 2.7-fold and 1.8-fold that of the commercial Pt/C and disordered PtCo catalysts, respectively. Additionally, the single cell employing the PtCo-800 catalyst showed a minimal voltage loss of only 27 mV at a current density of 2 A cm after 30,000 cycles of the accelerated durability test (ADT), underscoring its long-term stability. This work provides an efficient method for the preparation of high loading ORR electrocatalyst with excellent durability.