A fuel cell catalyst material includes metal catalyst particles formed of a metal material and a carbon-based coating composition at least partially coating at least some of the metal catalyst particles. The carbon-based coating composition includes a carbon network. The carbon-based coating composition is doped with a dopant. The carbon-based coating composition includes a number of defects formed by one or more vacated carbon atoms in the carbon network. The carbon-based coating composition is made from a non-aromatic carbon molecule.

A process for preparing a catalyst material, said catalyst material comprising a support material, a first metal and one or more second metals, wherein the first metal and the second metal(s) are alloyed and wherein the first metal is a platinum group metal and the second metal(s) is selected from the group of transition metals and tin provided the second metal(s) is different to the first metal is disclosed. The process comprises depositing a silicon oxide before or after deposition of the second metal(s), alloying the first and second metals and subsequently removing silicon oxide. A catalyst material prepared by this process is also disclosed.

A fuel cell cathode catalyst layer structure for enhancing the durability of a catalyst is provided. The cathode catalyst layer structure includes a first catalyst portion, a second catalyst portion, and a third catalyst portion that are arranged in sequence from an area close to a diffusion layer to an area close to a proton exchange membrane (PEM); a pure platinum catalyst is placed inside the first catalyst portion, the second catalyst portion, and the third catalyst portion; platinum loads of the pure platinum catalysts inside the first catalyst portion, the second catalyst portion, and the third catalyst portion decrease progressively; and average particle sizes of pure platinum catalyst particles inside the first catalyst portion, the second catalyst portion, and the third catalyst portion increase progressively. The pure platinum catalyst with a large or small particle size is more resistant to corrosion, and improves the initial performance of fuel cell.

A membrane electrode assembly includes a cathode, an anode and a proton-conductive membrane, wherein the cathode includes a first metal-containing catalyst and a proton-conductive ionomer, the anode includes a proton-conductive ionomer, a second metal-containing catalyst that catalyzes the reaction of hydrogen to protons, and a third metal-containing catalyst that catalyzes the reaction of CO to CO.sub.2, a total mass ratio of platinum of the second catalyst and platinum of the third catalyst to a total mass ratio of metals of the second catalyst and the third catalyst, with the exception of platinum, is greater than 3:1, and the total mass per unit area of platinum of the second catalyst and platinum of the third catalyst is less than 0.4 mg/cm.sup.2.

Catalysts comprising nanostructured elements comprising microstructured whiskers having an outer surface at least partially covered by a catalyst material comprising at least 90 atomic percent collectively Pt, Ni, and Cr, wherein the Pt is present in a range from 32.4 to 35.8 atomic percent, the Ni is present in a range from 57.7 to 63.7 atomic percent, and the Cr is present in a range from 0.5 to 10.0 atomic percent, and wherein the total atomic percent of Pt, Ni, and Cr equals 100. Catalyst described herein are useful, for example, in fuel cell membrane electrode assemblies.

Provided herein are catalyst materials comprising a catalyst support; and PtM′ nanowires affixed to the catalyst support, wherein the PtM′ nanowires include single atomic species of M′ at exterior surfaces of the PtM′ nanowires, and M′ represents at least one metal, e.g., a metal different from Pt. Also disclosed are manufacturing methods comprising: providing initial MM′ nanowires having an initial molar ratio of M:M′, wherein M is a noble metal, and M′ is a metal different from M; subjecting the initial MM′ nanowires to electrochemical dealloying to partially remove M′ and form partially dealloyed MM′ nanowires having a subsequent molar ratio of M:M′, wherein the subsequent molar ratio of M:M′ is greater than the initial molar ratio of M:M′; and affixing the partially dealloyed MM′ nanowires to a catalyst support.

An electrode material of a fibrous structure, has a platinum-based electrocatalytic material, an electrospinning polymer material, and an oxide material and/or one or more organophosphorus acid material with ion conduction. In the micromorphology has the structure of nanofibers, but also has porous morphological characteristics, the electrode material of this structure is prepared by electrostatic spinning technology, can be used as a high-temperature polymer electrolyte membrane fuel cell porous electrode.

A method of forming a fuel cell catalyst system, the method includes providing an anticorrosive, conductive catalyst support material having oxygen vacancies and a formula (I):
MgTi.sub.2O.sub.5-δ  (I),
where .sub.δ is any number between 0 and 3 optionally including a fractional part denoting the oxygen vacancies, coating the catalyst support material with a polymeric film, attaching a catalyst material onto the polymeric film, removing the polymeric film, and providing additional material onto the support material to increase physical, electrical, and/or mechanical contact between the catalyst material and the catalyst support material.

Provided is a method of preparing a ternary alloy catalyst that includes irradiating ultrasonic waves to a precursor admixture including a precursor of a noble metal, a precursor of a first transition metal, a precursor of a second transition metal, and a carrier. Particularly, the precursor of the second transition metal is an acetate-based precursor.

An electrode catalyst for an oxygen reduction reaction including intermetallic L1.sub.0-NiPtAg alloy nanoparticles having enhanced ORR activity and durability. The catalyst including intermetallic L1.sub.0-NiPtAg alloy nanoparticles is synthesized by employing silver (Ag) as a dopant and annealing under specific conditions to form the intermetallic structure. In one example, the intermetallic L1.sub.0-NiPtAg alloy nanoparticles are represented by the formula: Ni.sub.xPt.sub.yAg.sub.z wherein 0.4≤x≤0.6, 0.4≤y≤0.6, z≤0.1.