A successful
strategy for reducing the content of Pt without compromising
the activity of a Pt-based catalyst is to deposit Pt as an ultrathin
overlayer on the surface of another metal. Here, we report a facile
one-pot synthesis of Pd@Pt1L (1L: one atomic layer) core–shell
octahedra using a solution-phase method. The success of this method
relies on the use of metal precursors with markedly different reduction
kinetics. In a typical synthesis, the ratio between the initial reduction
rates of the Pd(II) and Pt(II) precursors differed by almost 100 times,
favoring the formation of Pd–Pt bimetallic octahedra with a
core–shell structure. The reduction of the Pt(II) precursor
at a very slow rate and the use of a high temperature allowed the
deposited Pt atoms to spread and cover the entire surface of Pd octahedral
seeds formed in the initial stage. More importantly, we were able
to scale up this synthesis using continuous-flow reactors without
compromising product quality. Compared to a commercial Pt/C catalyst,
the Pd@Pt1L core–shell octahedra showed major augmentation
in terms of catalytic activity and durability for the oxygen reduction
reaction (ORR). After 10000 cycles of accelerated durability test,
the core–shell octahedra still exhibited a mass activity of
0.45 A mg–1
Pt. We rationalized the experimental
results using DFT calculations, including the mechanism of synthesis,
ORR activities, and possible Pd–Pt atom swapping to enrich
the outermost layer with Pd. Specifically, the as-synthesized Pd@Pt1L octahedra tended to take a slightly mixed surface composition
because the deposited Pt atoms were able to substitute into Pd upon
deposition on the edges; ORR energetics were more favorable on pure
Pt shells as compared to significantly mixed Pd–Pt shells,
and the activation energy barriers calculated for the Pd–Pt
atom swapping were too prohibitive to significantly alter the surface
composition of the as-synthesized Pd@Pt1L octahedra, helping
sustain their activity for prolonged operation.