Balancing Activity and Stability through Compositional Engineering of Ternary PtNi–Au Alloy ORR Catalysts

Achieving the optimal balance between cost-efficiency and stability of oxygen reduction reaction (ORR) catalysts is currently among the key research focuses aiming at reaching a broader implementation of proton-exchange membrane fuel cells (PEMFCs). To address this challenge, we combine two well-established strategies to enhance both activity and stability of platinum-based ORR catalysts. Specifically, we prepare ternary PtNi–Au alloys, where each alloying element plays a distinct role: Ni reduces costs and boosts ORR activity, while Au enhances stability. A systematic comparative analysis of the activity–stability relationship for compositionally tuned PtNi–Au model layers, prepared by magnetron co-sputtering, was conducted using a diverse range of complementary characterization techniques and electrochemistry, supported by density functional theory calculations. Our study reveals that a progressive increase of the Au concentration in the Pt₅₀Ni₅₀ alloy from 3 to 15 at % leads to opposing catalyst activity and stability trends. Specifically, we observe a decrease in the ORR activity accompanied by an increase in catalyst stability, manifested in the suppression of both Pt and Ni dissolution. Despite the reduced activity compared to PtNi, the PtNi–Au alloy with 15 at % Au still exhibits nearly three times the activity of monometallic Pt. It also demonstrates a significantly improved dissolution stability relative to that of the PtNi alloy and even monometallic Pt. These findings provide valuable insights into the intricate balance between activity and stability in multimetallic ORR catalysts, paving the way for the design of cost-effective and durable materials for PEMFCs.