Hydrogen-fuelled proton-exchange membrane fuel cells (PEMFCs) offer a promising path towards zero-emission energy, but their commercialization is hindered by challenges, particularly in the cathode catalysts responsible for the oxygen reduction reaction (ORR). Current catalysts rely heavily on expensive platinum, which degrades quickly in the harsh cathodic environment. Efforts are thus focused on developing cost-effective and stable catalysts. Recent research has shown that alloying platinum with earth-abundant transition metals can reduce costs and improve ORR activity. Bimetallic Pt-M (M=Ni, Cu, Co, Fe, etc.) alloy catalysts, particularly those incorporating gold, have demonstrated superior performance. However, achieving both high activity and long-term stability remains a challenge. Our recent work emphasizes the importance of precise catalyst engineering to optimize both activity and durability, highlighting the need for a balanced alloy structure and compositional profile in Pt–Au catalysts.In this work, a magnetron co-sputtering technique was utilized to introduce a small amount of Au (5, 10, and 20 at%) into Pt50Ni50 alloy. The resulting ternary PtNiAu alloy demonstrated enhanced stability compared to PtNi, as evidenced by reduced platinum and nickel dissolution with increasing Au content, confirmed over a wide potential range up to 1.5 VRHE. On the other hand, at elevated concentrations, Au showed a detrimental effect on the ORR activity. Despite showing lower activity than PtNi, the ternary PtNiAu alloy still displayed superior activity compared to pure Pt. The investigation employed robust characterization methods, including synchrotron radiation photoelectron spectroscopy (SRPES), in-situ scanning flow cell coupled with inductively coupled plasma mass spectrometer (SFC-ICP-MS), and rotating disc electrode (RDE), to probe the composition-activity-stability relationship and identify the optimal Pt-Ni-Au composition meeting both high activity and stability requirements.
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