Simultaneous Improvements in Performance and Durability of an Octahedral PtNix/C Electrocatalyst for Next-Generation Fuel Cells by Continuous, Compressive, and Concave Pt Skin Layers

Simultaneous improvements in oxygen reduction reaction (ORR) activity and long-term durability of Pt-based cathode catalysts are indispensable for the development of next-generation polymer electrolyte fuel cells but are still a major dilemma. We present a robust octahedral core–shell PtNix/C electrocatalyst with high ORR performance (mass activity and surface specific activity 6.8–16.9 and 20.3–24.0 times larger than those of Pt/C, respectively) and durability (negligible loss after 10000 accelerated durability test (ADT) cycles). The key factors of the robust octahedral nanostructure (core–shell Pt73Ni27/C) responsible for the remarkable activity and durability were found to be three continuous Pt skin layers with 2.0–3.6% compressive strain, concave facet arrangements (concave defects and high coordination), a symmetric Pt/Ni distribution, and a Pt67Ni33 intermetallic core, as found by STEM-EDS, in situ XAFS, XPS, etc. The robust core–shell Pt73Ni27/C was produced by the partial release of the stress, Pt/Ni rearrangement, and dimension reduction of an as-synthesized octahedral Pt50Ni50/C with 3.6–6.7% compressive Pt skin layers by Ni leaching during the activation process. The present results on the tailored synthesis of the PtNix structure and composition and the better control of the robust catalytic architecture renew the current knowledge and viewpoint for instability of octahedral PtNix/C samples to provide a new insight into the development of next-generation PEFC cathode catalysts.