Development of alternative energy sources is crucial to tackle challenges encountered by the growing global energy demand. Hydrogen-fuel, a promising way to store energy produced from renewable power sources, can be converted into electrical energy at high efficiency via direct electrochemical conversion in fuel cells, releasing water as the sole byproduct. One important drawback to current fuel-cell technology is the high content of platinum-group-metal (PGM) electrocatalysts required to perform the sluggish oxygen reduction reaction (ORR). Addressing this challenge, remarkable progress has been made in the development of low-cost PGM-free electrocatalysts synthesized from inexpensive, earth-abundant, and easily sourced materials such as iron, nitrogen, and carbon (Fe-N-This article is protected by copyright. All rights reserved. C). PGM-free Fe-N-C electrocatalysts now exhibit ORR activities approaching that of PGM electrocatalysts but at a fraction of the cost, promising to significantly reduce overall fuel-cell technology costs. Herein, recent developments in PGM-free electrocatalysis, demonstrating increased fuel-cell performance, as well as efforts aimed at understanding the key limiting factor, i.e., the nature of the PGM-free active site, are summarized. Further improvements will be accomplished through the controlled and/or rationally designed synthesis of materials with higher active-site densities, while at the same time establishing methods to mitigate catalyst degradation.

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This article reports on the characterization of polymer electrolyte fuel cell (PEFC) cathodes featuring a platinum group metal-free (PGM-free) catalyst using nanoscale resolution X-ray computed tomography (nano-CT) and morphological analysis. PGM-free PEFC cathodes have gained significant interest in the past decade since they have the potential to dramatically reduce PEFC costs by eliminating the large platinum (Pt) raw material cost. However, several challenges remain before they are commercially viable. Since these catalysts have lower volumetric activity, the PGM-free cathodes are thicker and subject to increased gas and proton transport resistances that reduce the performance. To better understand the efficacy of the catalyst and improve electrode performance, a detailed understanding the correlation between electrode fabrication, morphology, and performance is crucial. In this work, the pore/solid structure and the ionomer distribution was resolved in three dimensions (3D) using nano-CT for three PGM-free electrodes of varying Nafion loading. The associated transport properties were evaluated from pore/particle-scale simulations within the nano-CT-imaged structure. These characterizations are then used to elucidate the microstructural origins of the dramatic changes in fuel cell performance with varying Nafion ionomer loading. We show that this is primarily a result of distinct changes in ionomer's spatial distribution. The significant impact of electrode morphology on performance highlights the importance of PGM-free electrode development in concert with efforts to improve catalyst activity and durability.

Replacement of platinum-based electrocatalysts to facilitate the oxygen reduction reaction (ORR) in proton exchange fuel cells remains an outstanding challenge. Significant progress in the development of platinum group metal-free (PGM-free) electrocatalysts has been reported but a fundamental understanding of how these materials catalyze the ORR remains elusive. In this work, we report our efforts to synthesize and characterize PGM-free electrocatalysts with different transition metals (M = Fe, Co, and Mn) in order to better understand the most plausible active site structures and ORR reaction pathways. Our findings indicate that PGM-free electrocatalysts synthesized via a dual nitrogen precursor, polyaniline and cyanamide, synthesis process but with varied transition metal precursors resulted in the following ORR activity trend: Fe > Co > Mn. Furthermore, similar densities of active sites across the three synthesized materials were calculated using an established molecular probe technique. The relative experimental activities are consistent with trends determined via density functional theory (DFT) modeling that suggests spontaneous OH ligand modification of active sites.