Shape-controlled octahedral Pt-Ni alloy nanoparticles exhibit remarkably high activities for the electroreduction of molecular oxygen (oxygen reduction reaction, ORR), which makes them fuel-cell cathode catalysts with exceptional potential. To unfold their full and optimized catalytic activity and stability, however, the nano-octahedra require post-synthesis thermal treatments, which alter the surface atomic structure and composition of the crystal facets. Here, we address and strive to elucidate the underlying surface chemical processes using a combination of ex situ analytical techniques with in situ transmission electron microscopy (TEM), in situ X-ray diffraction (XRD), and in situ electrochemical Fourier transformed infrared (FTIR) experiments. We present a robust fundamental correlation between annealing temperature and catalytic activity, where a ∼25 times higher ORR activity than for commercial Pt/C (2.7 A mg at 0.9 V) was reproducibly observed upon annealing at 300 °C. The electrochemical stability, however, peaked out at the most severe heat treatments at 500 °C. Aberration-corrected scanning transmission electron microscopy and energy-dispersive X-ray spectroscopy (EDX) in combination with in situ electrochemical CO stripping/FTIR data revealed subtle, but important, differences in the formation and chemical nature of Pt-rich and Ni-rich surface domains in the octahedral (111) facets. Estimating trends in surface chemisorption energies from in situ electrochemical CO/FTIR investigations suggested that balanced annealing generates an optimal degree of Pt surface enrichment, while the others exhibited mostly Ni-rich facets. The insights from our study are quite generally valid and aid in developing suitable post-synthesis thermal treatments for other alloy nanocatalysts as well.

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Water electrolysis is the key to a decarbonized energy system, as it enables the conversion and storage of renewably generated intermittent electricity in the form of hydrogen. However, reliability challenges arising from titanium‐based porous transport layers (PTLs) have hitherto restricted the deployment of next‐generation water‐splitting devices. Here, it is shown for the first time how PTLs can be adapted so that their interface remains well protected and resistant to corrosion across ≈4000 h under real electrolysis conditions. It is also demonstrated that the malfunctioning of unprotected PTLs is a result triggered by additional fatal degradation mechanisms over the anodic catalyst layer beyond the impacts expected from iridium oxide stability. Now, superior durability and efficiency in water electrolyzers can be achieved over extended periods of operation with less‐expensive PTLs with proper protection, which can be explained by the detailed reconstruction of the interface between the different elements, materials, layers, and components presented in this work.

Knowledge of degradation pathways of catalyst/support ensembles aids the development of rational strategies to improve their stability. Here, this is exemplified using indium tin oxide (ITO)-supported Platinum nanoparticles as electrocatalysts at fuel cell (FC) cathodes under degradation protocols to mimic operating conditions in two potential regimes. The evolution of crystal structure, composition, crystallite and particle size is tracked by in situ X-ray techniques (small and wide angle scattering), metal dissolution by in situ scanning flow cell coupled with mass spectrometry (SFC ICP-MS) and Pt surface morphology by advanced electron microscopy. In a regular FC operation regime, Pt poisoning rather than Pt particle growth, agglomeration, dissolution or detachment was found to be the likely origin of the observed degradation and ORR activity losses. In the start-up regime degradation is actually suppressed and only minor losses in catalytic activity are observed. The presented data thus highlight the excellent nanoparticle stabilization and corrosion resistance of the ITO support, yet point to a degradation pathway involving Pt surface modifications by deposition of sub-monolayers of support metal ions. The identified degradation pathway of the Pt/oxide catalyst/support couple contributes to our understanding of cathode electrocatalysts for polymer electrolyte fuel cells (PEFC)