The design of active and robust bimetallic nanoparticle catalysts requires the control of the nanoscale alloying and phase-segregation structures and the correlation between the nanoscale phase structures and the catalytic properties. Here we describe new findings of a detailed investigation of such nanoscale phase structures and their structure-catalytic activity correlation for gold-platinum nanoparticles prepared with controllable sizes and compositions. The nanoscale alloying and phase-segregation were probed as a function of composition, size, and thermal treatment conditions using X-ray diffraction, X-ray photoelectron spectroscopy, high-resolution transmission electron microscopy, electrochemical characterization, and density functional theory modeling. The results have provided the experimental evidence in support of the theoretically simulated dependence of alloying and phase segregation on particle size and temperature. More importantly, new insights have been gained into the control of the nanoscale phase properties of this bimetallic system among alloyed, partially alloyed, or partially phase segregated structures. In contrast to the largely alloyed character for the catalysts treated at 300-400°C, the higher-temperature treated catalysts (e.g., 800°C) are shown to consist of a Pt-rich alloy core and a Au shell or a phase-segregated Au domains enriched on the surface. This conclusion is further supported by the electrochemical and electrocatalytic data revealing that the catalytic activity is highly dependent on the nanoscale evolution of alloying and phase segregation. The thermal control of the nanoscale alloying, phase-segregation, and core-shell evolution of the nanoscale bimetallic catalysts provided the first example for establishing the correlation between the nanoscale phase structures and the electrocatalytic activity for oxygen reduction reaction correlation, which has profound implications to the design and nanoengineering of a wide variety of bimetallic or multimetallic nanostructures for advanced catalysts.

The ability to nanoengineer catalysts in terms of size, composition, shape, and phase properties is essential in exploiting the catalytic properties. This paper reports the results of an investigation of the structural and electrocatalytic properties of PtM (M = Co and Ni) nanoparticles and their carbon-supported electrocatalysts for an oxygen reduction reaction (ORR). Examples are focused on PtCo and PtNi nanoparticles in the range of 2−9 nm and in the composition range of 50−75% Pt. A sharp contrast in size dependence of the activity was revealed between PtCo/C and PtNi/C catalysts, showing a clear trend of decrease in activity with increasing particle size for PtCo/C and a subtle increase in activity for PtNi/C. The size−activity correlation also depends on the bimetallic composition. The detailed analyses of the structures of the catalysts by XAS technique revealed important information for assessing the electrocatalytic properties in relation to the relative amount of oxygenated species and the relative change in interatomic bond distance in the bimetallic nanoparticles, which suggest that a combination of structural parameters such as the change in Pt−Pt bond distance, the segregation of metal phases, and the formation of surface oxygenated species is operative for the size dependence of the enhanced electrocatalytic activity.

One of the most important challenges for the ultimate commercialization of fuel cells is the preparation of active, robust, and low-cost catalysts. This review highlights some findings of our investigations in the last few years in developing advanced approaches to nanostructured catalysts that address this challenge. Emphasis is placed on nanoengineering-based fabrication, processing, and characterization of multimetallic nanoparticles with controllable size (1-10 nm), shape, composition (e.g. Ml(n)M2(100-n), M1(n)M2(m)M3(100-n-m), M1@M2, where M (1 or 2) = Pt, Co, Ni, V, Fe, Cu, Pd, W, Ag, Au etc) and morphology (e.g. alloy, core@shell etc). In addition to an overview of the fundamental issues and the recent progress in fuel cell catalysts, results from evaluations of the electrocatalytic performance of nanoengineered catalysts in fuel cell reactions are discussed. This approach differs from other traditional approaches to the preparation of supported catalysts in the ability to control the particle size, composition, phase, and surface properties. An understanding of how the nanoscale properties of the multimetallic nanoparticles differ from their bulk-scale counterparts, and how the interaction between the nanoparticles and the support materials relates to the size sintering or evolution in the thermal activation process, is also discussed. The fact that the bimetallic gold-platinum nanoparticle system displays a single-phase character different from the miscibility gap known for its bulk-scale counterpart serves as an important indication of the nanoscale manipulation of the structural properties, which is useful for refining the design and preparation of the bimetallic catalysts. The insight gained from probing how nanoparticle-nanoparticle and nanoparticle-substrate interactions relate to the size evolution in the activation process of nanoparticles on planar substrates serves as an important guiding principle in the control of nanoparticle sintering on different support materials. The fact that some of the trimetallic nanoparticle catalysts (e.g. PtVFe or PtNiFe) exhibit electrocatalytic activities in fuel cell reactions which are four-five times higher than in pure Pt catalysts constitutes the basis for further exploration of a variety of multimetallic combinations. The fundamental insights into the control of nanoscale alloy, composition, and core-shell structures have important implications in identifying nanostructured fuel cell catalysts with an optimized balance of catalytic activity and stability.

The ability to control the nanoscale size, composition, phase, and facet of multimetallic catalysts is important for advancing the design and preparation of advanced catalysts. This report describes the results of an investigation of the thermal treatment temperature on nanoengineered platinum−nickel−cobalt catalysts for oxygen reduction reaction, focusing on understanding the effects of lattice strain and surface properties on activity and stability. The thermal treatment temperatures ranged from 400 to 926 °C. The catalysts were characterized by microscopic, spectroscopic, and electrochemical techniques for establishing the correlation between the electrocatalytic properties and the catalyst structures. The composition, size, and phase properties of the trimetallic nanoparticles were controllable by our synthesis and processing approach. The increase in the thermal treatment temperature of the carbon-supported catalysts was shown to lead to a gradual shrinkage of the lattice constants of the alloys and an enhanced population of facets on the nanoparticle catalysts. A combination of the lattice shrinkage and the surface enrichment of nanocrystal facets on the nanoparticle catalysts as a result of the increased temperature was shown to play a major role in enhancing the electrocatalytic activity for catalysts. Detailed analyses of the oxidation states, atomic distributions, and interatomic distances revealed a certain degree of changes in Co enrichment and surface Co oxides as a function of the thermal treatment temperature. These findings provided important insights into the correlation between the electrocatalytic activity/stability and the nanostructural parameters (lattice strain, surface oxidation state, and distribution) of the nanoengineered trimetallic catalysts.

The formation of nanosized alloys between a pair of elements, which are largely immiscible in bulk, is examined in the archetypical case of Pt and Au. Element specific resonant high-energy X-ray diffraction experiments coupled to atomic pair distribution functions analysis and computer simulations prove the formation of Pt-Au alloys in particles less than 10 nm in size. In the alloys, Au-Au and Pt-Pt bond lengths differing in 0.1 Å are present leading to extra structural distortions as compared to pure Pt and Au particles. The alloys are found to be stable over a wide range of Pt-Au compositions and temperatures contrary to what current theory predicts. The alloy-type structure of Pt-Au nanoparticles comes along with a high catalytic activity for electrooxidation of methanol making an excellent example of the synergistic effect of alloying at the nanoscale on functional properties.