A high-throughput study of PtNiZr catalysts for application in PEM fuel cells

The effects of adding Zr to PtNi oxygen reduction reaction (ORR) electrocatalyst alloys were examined in a study aimed at probing the possibility of creating catalysts with enhanced resistance to corrosion in a PEM fuel cell environment. Samples consisting of pure Pt or PtNiZr alloys with a range of compositions (not exceeding 11 at.% Zr) were fabricated using co-sputter deposition. A high-throughput fabrication approach was used wherein 18 distinct thin film catalyst alloy samples with varying compositions were deposited onto a large-area substrate with individual Au current collector structures. A multi-channel pseudo-potentiostat allowed for the simultaneous quantitative study of catalytic activity for all 18 electrodes in a single test bath, a first for the study of ORR electrocatalysts. A properly stirred oxygenated 1 M H2SO4 electrolyte solution was used to provide each electrode with a steady-state flow of reactants during electrochemical evaluation. The onset potentials, absolute current density values, and Tafel analysis data obtained using this technique were compared with literature reports. The analyses showed that most PtNiZr alloys tested offered improvements over pure Pt, however those surfaces with a high mole fraction (>4 at.%) of Zr exhibited reduced activity that was roughly inversely correlated to the amount of Zr present. Film composition, morphology, and crystallographic properties were examined using X-ray energy dispersive spectroscopy (XEDS), X-ray photoelectron spectroscopy (XPS), SEM, and synchrotron X-ray diffraction. These data were then correlated with electrochemical data to elucidate the relationships between composition, structure, and relative performance for this ternary system.