Material Changes of Bimetallic Ag–Cr, Fe, Co, Ni, Cu, Sn Electrocatalysts during Alkaline Oxygen Reduction in Fundamental Versus Alkaline Membrane Exchange Fuel Cell Conditions

Abstract

The more apparent challenges of climate change drastically increase the global demand for sustainable fuel production and usage.1 In this context, hydrogen fuel cells (FCs) powered by renewable electricity are among the promising technologies.2 Addressing the sluggish cathode reaction in FCs, the oxygen reduction reaction (ORR), these devices hold immense potential for sustainable energy conversion and storage. An alkaline environment allows for the utilization of more abundant and cost-effective metals in contrast to current platinum-based catalysts. Silver (Ag), for instance, exhibits high selectivity for the ORR, i.e., forming hydroxide instead of peroxide.3 When combined with secondary metals, bimetallic Ag catalysts show enhanced activity, making them viable alternatives to platinum-group materials for ORR.In our highly collaborative research, we investigated the material transformations of bimetallic Ag thin films with chromium (Cr), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), and tin (Sn) as secondary metals for ORR electrocatalysis in fundamental rotating disk electrode (RDE) setups and the application device, anion-exchange membrane FC (AEMFC). Grazing-incidence X-ray diffraction (GI-XRD) conducted prior to electrochemical testing reveals no evidence of alloying except for the Ag-Sn bimetallic thin film. However, X-ray photoelectron spectroscopy (XPS) indicates a shift of the Ag 3d peaks to higher binding energies for all catalysts, suggesting a hybridization of Ag and the secondary metals. The composition of the metal surface, native oxide formation, ORR performance, and material changes post-RDE testing vary distinctly among the Ag bimetallic catalysts depending on the secondary metal. Intriguingly, performance is either enhanced (Ag-Co, Ag-Sn), maintained with reduced Ag content (Ag-Fe, Ag-Cr), or falls in between the two monometallic materials (Ag-Ni) compared to monometallic Ag thin films. Density functional theory (DFT) calculations offer insights into the catalyst performances and changes in metal oxidation states and surface composition prior and post electrocatalysis. AEMFC tests reveal promising performances under device conditions contradicting our fundamental RDE measurements. The integration of fundamental and application device tests, along with material characterization and DFT calculations, enables a comprehensive exploration of material changes under varying electrochemical conditions. This underscores the complexity of bimetallic catalysts and the importance of testing under device conditions, positioning Ag-bimetallic catalysts as highly promising alternatives to platinum-group metal catalysts for alkaline ORR.