No abstract

Combinatorial methods have been applied to the preparation and screening of fuel cell electrocatalysts. Hardware and software have been developed for fast sequential measurements of cyclic voltammetric and steady-state currents in 64-element half-cell arrays. The arrays were designed for the screening of high-surface-area supported electrocatalysts. Analysis software developed allowed the semiautomated processing of the large quantities of data, applying filters that defined figures of merit relevant to fuel cell catalyst activity and tolerance. Results are presented on the screening of carbon-supported platinum catalysts of varying platinum metal loading on carbon (and thus, particle size) in order to demonstrate the speed and sensitivity of the screening methodology. CO electro-oxidation, oxygen reduction, and methanol oxidation on a series of such catalysts reveal clear trends in characteristics and activities. Catalysts with smaller particle sizes reveal structure in the CO stripping voltammetry that can be associated with edge sites in addition to the closely packed planes, and this is concomitantly reduced as particle size is increased. Specific activity for steady-state methanol oxidation and oxygen reduction at room temperature in H(2)SO(4) electrolyte is found to be a maximum for the largest particle sizes, in agreement with the literature. These trends in activity are significantly smaller than the differences in activities of promoted platinum-based alloy catalysts for the same reaction.

A method that combines co-evaporation of pure elements from multiple finite-size sources on temperature-controlled substrates with independently controlled source shutters has been used for the synthesis of solid-state material combinatorial libraries. The source shutters are positioned to achieve a controlled gradient of the deposited elements across the substrate and are fixed during the course of deposition. Choice of the shutter position and the rate of deposition for each source allow the direct synthesis of continuous and controlled materials of varying composition. There are significant advantages of the method over alternatives which rely on sequential deposition and subsequent heat treatment to produce thin film materials. The parameters governing the creation of gradients have been identified and defined. Simulations and experimental data have been compared in the case of a single source. Results are presented for the synthesis of a ternary alloy library to demonstrate the methodology.

A novel high-throughput technique has been developed for the investigation of the influence of supported metal particle size and the support on electrocatalytic activity. Arrays with a gradation of catalyst particle sizes are fabricated in a physical vapor deposition system that also allows selection of the support material. Simultaneous electrochemical measurements at all electrodes in the array, together with determination of the actual particle size distribution on each of the electrodes by transmission electron microscopy (TEM), then allows rapid determination of the activity as a function of catalyst center size. The procedure is illustrated using data for the reduction of oxygen on gold nanoparticles supported on both substoichiometric titanium dioxide (TiO(x)()) and carbon and the conclusions are verified using voltammetry at rotating disk electrodes. Gold centers with diameters in the range 1.4-6.3 nm were investigated and it is demonstrated that, with both supports, the catalytic activity for oxygen reduction decays rapidly for particle sizes below 3.0 nm. This may be observed as a decrease in current at constant potential or an increase in the overpotential for oxygen reduction.

We report the application of a new method for the high-throughput synthesis and screening of thin film materials and its application to the discovery of electrocatalysts. Results are presented for the PtPdAu ternary alloy system with respect to activity for oxygen reduction. The results reveal an enhancement in activity for a range of PtPd alloy compositions over either of the pure elements. An optimum composition range of ternary alloys with significant activity was also identified. A correlation was also investigated between the surface reduction potential and the activity for oxygen reduction in both binary and ternary alloys. The results demonstrate the potential of the methodology for the discovery and optimization of electrocatalysts for a wide range of applications.