Proton-exchange membrane fuel cell technology is a key component in the future zero-carbon energy system, generating power from carbon-free fuels, such as green hydrogen. However, the high Pt loading in conventional fuel cell electrodes to maintain electrocatalytic activity and durability, especially on the cathode for oxygen reduction, is the Achilles heel for the worldwide deployment of fuel cell technologies. To minimize Pt consumption for oxygen reduction, we synthesized Pt-Co-based electrocatalysts with meticulous structuring from micrometer to the atomic scale based on reaction pathways. The resulting Pt-Co-based electrocatalysts contain only 1.9 wt% Pt, which is 20 times lower than the conventional Pt-C catalysts for fuel cells. By utilizing electrospinning and in situ synthesis, we anchored three-dimensionally structured zeolitic imidazolate frameworks on continuously connected nanofibrous electrospun mats. The Pt-Co@Pt-free nanowire (PC@PFN) electrocatalysts contain Pt-Co nanoparticles (NPs) and non-Pt elements, Co-containing sites comprising NPs, nanoclusters, and N-coordinated Co single atoms. Despite the ultralow Pt loading in PC@PFN, the mass activity exceeds the U.S. Department of Energy 2025 target by 2.8 times and retains 85.5% of the initial activity after 80,000 durability test cycles, possibly owing to synergistic reaction pathways between Pt and non-Pt sites.
Keywords: Pt–Co alloy; atomically dispersed Co; low Pt loading; oxygen reduction reaction; proton-exchange membrane fuel cell; synergistic effect; zeolitic imidazolate framework.