Recent non-precious-metal catalysts
(NPMCs) show promise to replace
in the future platinum-based catalysts currently needed for the electroreduction
of oxygen (ORR) in proton-exchange membrane fuel cells (PEMFCs). Among
NPMCs, the most mature subclass of materials is prepared via the pyrolysis
of metal (Fe and Co), nitrogen, and carbon precursors (labeled as
metal–NC). Such materials often comprise different types of
nitrogen groups and metal species, from atomically dispersed metal
ions coordinated to nitrogen to metallic or metal–carbide particles,
partially or completely embedded in graphene shells. While disentangling
the different contributions of these species to the initial ORR activity
of metal–NC catalysts with multidunous active sites is complex,
following the fate of these different active sites during electrochemical
aging is even more difficult. To shed light onto this, herein, six
metal–NC catalysts were synthesized and characterized before/after
aging with two different accelerated stress tests (AST) simulating
PEMFC cathode operating conditions either in steady-state or transient
conditions. The samples differed from each other by the nature of
the metal (Fe or Co), the metal content, and the heating mode applied
during pyrolysis. Catalysts featuring either only atomically dispersed
metal-ion sites (metal–N
x
C
y
) or only metal nanoparticles encapsulated
in the carbon matrix (metal@N–C) were obtained after pyrolysis
of catalyst precursors containing 0.5 or 5.0 wt % of metal, respectively.
All six catalysts showed high beginning-of-life ORR mass activity,
but the ASTs revealed marked differences in their ORR activity at
end-of-life. After the load-cycling AST (10000 cycles), metal–NC
catalysts with metal–N
x
C
y
sites retained most of their initial activity at
0.8 V (60–100%), while those with metal@N–C particles
retained only a small fraction of initial activity (10–20%).
Metal–NC catalysts with metal–N
x
C
y
sites lost only 25% of their
initial ORR activity after 30000 load cycles at 80 °C, thereby
reaching the 2020 stability target defined by US Department of Energy.
After 10000 start-up/shut-down cycles, no catalyst showed measurable
ORR activity at 0.8 V. However, after 1000 start-up/shut-down cycles,
most of the metal–NC catalysts initially comprising metal–N
x
C
y
sites showed
measurable ORR activity at 0.8 V, while those initially comprising
metal@N–C particles did not. Energy-dispersive X-ray spectroscopy
and Raman spectroscopy measurements of the cycled rotating disk electrodes
revealed that demetalation of the catalytic centers and corrosion
of the carbon matrix are the main causes of ORR activity decay during
load-cycling and start-up/shut-down cycling, respectively. In contrast
to what could have been intuitively expected, the metal–N
x
C
y
sites are
more robust to both demetalation and carbon corrosion than metal@N–C
sites.