The large-scale commercialization
of the PEMFCs is hindered
due
to the high cost of the Pt-based electrocatalysts (Pt/C) and the low
durability associated with the oxidation of the carbon support in
Pt/C. Many Pt-based carbon-free electrocatalysts have been explored,
exhibiting excellent stability and activity, but the performance is
further expected to be improved by developing suitable Pt alloy catalysts
based on the carbon-free supports. To explore this possibility, we
have developed a PtNi/SiO2 alloy system, which acts as
a carbon-free electrocatalyst exhibiting enhanced activity for the
oxygen reduction reaction (ORR). A half-cell study of PtNi/SiO2 (45 wt%) shows ∼4.3 times higher ORR activity compared
to the state-of-the-art Pt/C (40%). The uniform distribution of the
PtNi nanoparticles over SiO2 is the crucial feature of
the catalyst. PtNi/SiO2 shows better durability even after
5000 cycles compared to the state-of-the-art Pt/C. The catalyst shows
a negative shift in the half-wave potential (E
1/2) by only 5 mV, which is lower than that of the 11 mV drop
incurred by Pt/C. Considering this high activity of the PtNi/SiO2 catalyst for the ORR, we tried to explore the possibility
of demonstrating a single-cell PEMFC in the MEA by pairing the catalyst
as the cathode along with the Pt/C as the anode. This paired configuration
of the single cell is found to be providing promising performance
by delivering a current density of 960 mA/cm2 at 0.60 V
and a maximum power density of 835 mW/cm2. Thus, this study
outlines the possibility of developing potential alloy combinations
of Pt on carbon-free substrates and then deploying them as electrodes
for PEMFC applications. In the context of mitigating the carbon corrosion-related
issues without compromising the intrinsic activities of the catalysts,
the development of suitable alloy combinations on various carbon-free
substrates is of significant technological advantages. The formation
of the alloy phase along with the fine and uniform distribution of
the alloy nanoparticles on the SiO2 substrate, followed
by its successful deployment as the cathode of a single cell, points
toward the scope of exploring material developments in this direction.