Low-Pt NiNC-supported PtNi nanoalloy oxygen reduction reaction electrocatalysts—In situ tracking of the atomic alloying process

Carbon-supported platinum-nickel (Pt-Ni) alloy nanoparticles (NPs) emerge as the electrocatalysts of choice for deployment in polymer electrolyte membrane fuel cell (PEMFC) cathodes. To date, viable PtNi nanoalloy catalysts are characterized by large Pt weight loading of up to 50 wt%. To a large extent, their preparation processes often involve the use of expensive or even hazardous organometallic metal precursors, solvents and capping agents, substantially limiting their synthetic scalability and sustainability. Here, we report a novel synthetic strategy toward highly active low-Pt loaded PtNi nanoalloy Oxygen Reduction Reaction (ORR) catalysts. The synthesis involves the Pyrolysis and Leaching of Ni-organic polymers, subsequent Pt nanoparticle Deposition followed by thermal Alloying (referred to as PLDA) to prepare single Ni atom site (NiNC)-supported bimetallic PtNi nanoalloy electrocatalysts with very low Pt weight contents of 3–5 wt% Pt loading. We demonstrate that despite this low Pt weight loading, the catalysts exhibit more favorable Pt-mass activities compared to conventional, carbon-supported 20–30 wt%Pt Pt-loaded benchmark PtNi alloy catalysts. Using in situ transmission electron microscopy, cyclic voltammetry, and surface CO stripping techniques, we track and unravel the key stages of the formation process of the PtNi nanoparticle catalysts directly at the atomic scale. By carefully chosen reference experiments, we find that carbon-encapsulated Ni NPs, rather than NiNx single sites, serve exclusively as the Ni atom source for PtNi alloy formation during thermal treatments. Our materials concepts offer a pathway to further decrease the overall Pt content of PEM fuel cell devices.