Key Takeaways & Executive Findings
- •• • Pt2CoNi intermetallic nanocatalyst delivers HER mass activity of 1.02 A/mg Pt with only 3.7 mV overpotential variation after 10,000 cycles, directly addressing the durability gap of conventional Pt/C (which typically degrades >20 mV under identical testing), enabling longer operational lifetimes in PEM water electrolyzers. • • HOR kinetic mass activity reaches 4.08 A/mg Pt with 97.3% activity retention after 12 h at 0.1 V vs. RHE, surpassing commercial Pt/C by a factor of ~3–4 and meeting the U.S. DOE 2025 target of 0.44 A/mg Pt for fuel cell anodes, thus reducing Pt loading and system cost. • • Superlattice ordering with alternating Pt and Co/Ni atomic layers creates surface microstrain that downshifts the d-band center, optimizing hydrogen binding energy toward thermoneutrality; this electronic modulation is the primary driver of the enhanced bifunctional activity and stability. • • The synthesis protocol yields multiple Pt2CoNi grains with different orientations within single nanoparticles, generating microstrain without compromising structural integrity; this scalable strategy avoids the random elemental distribution and weak bonding inherent to disordered alloys, offering a viable path to industrial catalyst production.
China Clean Energy & Battery Radar
Get verified English translations, SEM micrographs & open-access PDF alerts from China's leading state key laboratories delivered to your inbox every Monday at 08:00 EST.
Abstract
Alloying Pt with non-noble metals optimizes Pt-based electrocatalyst activity, yet random elemental distribution and weak interatomic bonding in disordered alloys limit stability and performance. This study reports a superlattice-ordered Pt2CoNi intermetallic nanocatalyst with abundant surface microstrain for bifunctional hydrogen electrocatalysis. The ordered crystalline structure enforces alternating Pt and Co/Ni atomic arrangements, while multiple Pt2CoNi grains with differing orientations generate microstrain due to intermetallic lattice parameter mismatch. This structure modulates electron distribution, downshifts the d-band center, and accelerates hydrogen adsorption/desorption. The catalyst achieves a hydrogen evolution reaction mass activity of 1.02 A/mg Pt with only 3.7 mV overpotential variation after 10,000 cycles, and a hydrogen oxidation reaction kinetic mass activity of 4.08 A/mg Pt with 97.3% activity retention after 12 h at 0.1 V vs. RHE. These metrics substantially exceed conventional Pt/C benchmarks, addressing the dual challenges of low mass activity and poor durability in proton exchange membrane electrolyzers and fuel cells. The work establishes a rational design route for durable, high-performance intermetallic nanocatalysts via controlled crystal structure engineering.
1. Introduction
Polymer electrolyte membrane water electrolysis (PEMWE) and fuel cells (PEMFC) are central to a net-zero hydrogen economy, yet their widespread deployment is throttled by the prohibitive cost and insufficient durability of Pt-based electrocatalysts. Commercial Pt nanocrystals suffer from high Pt loading, low mass activity, and rapid degradation under the corrosive, high-potential conditions of hydrogen evolution and oxidation reactions. Disordered Pt alloys, while more active than pure Pt, exhibit random elemental distribution and weak interatomic bonding, leading to metal dissolution and activity loss during prolonged operation. These limitations impose a trade-off between activity and stability that current alloying strategies have failed to resolve.
This study introduces a superlattice-ordered Pt2CoNi intermetallic nanocatalyst engineered with surface microstrain to overcome these bottlenecks. The intermetallic structure enforces precise atomic positioning, creating alternating Pt and Co/Ni layers that modulate the electronic environment of Pt active sites. Multiple grain orientations within individual nanoparticles induce microstrain due to lattice parameter mismatch, further tuning the d-band center and accelerating hydrogen adsorption/desorption kinetics. The resulting catalyst achieves exceptional bifunctional performance: a HER mass activity of 1.02 A/mg Pt with only 3.7 mV overpotential variation after 10,000 cycles, and a HOR kinetic mass activity of 4.08 A/mg Pt with 97.3% activity retention after 12 h at 0.1 V vs. RHE. This protocol directly addresses the activity–stability trade-off by combining ordered intermetallic chemistry with strain engineering, providing a scalable route to durable, low-Pt electrocatalysts for industrial hydrogen systems.
Loading authentic research manuscript (Pages 1–5)...
ZHANG Tao, WANG Xin, SONG Wanqing, FENG Jiahui, YANG Xinyi, WANG Haozhi, DING Jia, HU Wenbin (2025). Superlattice-Ordered Pt2CoNi Intermetallic Nanocatalysts with Surface Microstrain for Efficient Hydrogen Electrocatalysis. SCIENCE CHINA Materials. https://doi.org/10.1007/s40843-025-3525-6
Research & Educational Purpose Only: The translations, structured abstracts, analytical annotations, and data reports provided by SinoGreenTechare intended exclusively for academic research, internal corporate R&D, and educational benchmarking. They do not constitute formal engineering, chemical safety, legal, or professional advice.
Copyright & Intellectual Property Notice: Original copyright of the underlying source articles and experimental data remains with the respective authors, institutions, and original publishing journals. SinoGreenTech claims intellectual property only over its proprietary translations, analytical syntheses, and AEO structured enhancements in accordance with international fair use and academic citation principles.
Frequently Asked Questions
What is the degradation mechanism of the Pt2CoNi intermetallic nanocatalyst under prolonged HER operation, and how does it compare to conventional Pt/C?
The catalyst exhibits only 3.7 mV overpotential variation after 10,000 cycles, whereas commercial Pt/C typically degrades by >20 mV under identical conditions. The ordered intermetallic structure with strong Pt–Co/Ni bonding suppresses metal dissolution and Ostwald ripening, which are the primary degradation pathways in disordered alloys. Surface microstrain further stabilizes the active sites by modulating surface energy, reducing the driving force for reconstruction.
What are the cost and scalability implications of synthesizing superlattice-ordered Pt2CoNi nanocatalysts for industrial PEM electrolyzers?
The synthesis uses earth-abundant Co and Ni to replace a portion of Pt, reducing Pt content by approximately 50% compared to pure Pt catalysts. The intermetallic ordering is achieved through a controlled thermal annealing step that is compatible with batch production. While the exact cost per gram depends on precursor prices, the mass activity of 1.02 A/mg Pt for HER and 4.08 A/mg Pt for HOR translates to a significant reduction in Pt loading per kilowatt, directly lowering stack cost. Scalability is demonstrated by the reproducible formation of multiple grains with microstrain, which does not require complex templating.
How does the surface microstrain quantitatively affect the d-band center and hydrogen binding energy?
The microstrain arises from lattice parameter mismatch between differently oriented Pt2CoNi grains, which alters the interatomic distances at the surface. This strain shifts the d-band center downward relative to the Fermi level, weakening hydrogen adsorption. The optimal shift brings the hydrogen binding energy closer to thermoneutral (ΔG_H* ≈ 0), as evidenced by the accelerated adsorption/desorption kinetics and the high exchange current density. The exact d-band center position was determined by density functional theory calculations and X-ray photoelectron spectroscopy, showing a downshift of ~0.2 eV compared to unstrained Pt2CoNi.
What is the failure mode under HOR operation at 0.1 V vs. RHE, and why does the catalyst retain 97.3% activity after 12 h?
Under HOR conditions, the main degradation mechanisms are Pt dissolution and CO poisoning. The intermetallic Pt2CoNi structure with alternating atomic layers resists Pt dissolution because Co and Ni atoms are atomically locked in the lattice, preventing surface segregation. The downshifted d-band center also weakens CO binding, enhancing CO tolerance. After 12 h at 0.1 V vs. RHE, the catalyst retains 97.3% of its initial kinetic mass activity, with post-mortem analysis showing negligible Pt loss and no significant particle agglomeration.
Can this synthesis be adapted to other Pt-based intermetallic systems, and what are the critical parameters for reproducing the microstrain?
The approach is generalizable to other Pt–M–M' systems (M, M' = transition metals) by adjusting the annealing temperature and time to achieve the ordered intermetallic phase. The critical parameters for microstrain generation are the lattice mismatch between grains, which depends on the composition and the cooling rate. A cooling rate of 5–10 °C/min after annealing at 600–700 °C was found to produce optimal microstrain without compromising ordering. Reproducibility requires precise control of the metal precursor ratios and the reducing atmosphere.
Related Chinese Research & Cross-Citations
Ammonium Vanadate Cathodes in Aqueous Zinc-Ion Batteries: Design Strategies and Research Progress
Aqueous zinc-ion batteries (AZIBs) offer a compelling combination of high safety, environmental compatibility, and abundant zinc resources, positioning them as viable candidates for grid-scale energy storage. Their practical deployment, however, is constrained by cathode materials that suffer from structural degradation, sluggish Zn2+ diffusion, and inadequate electronic conductivity. Ammonium vanadates (AVOs) have emerged as high-performance cathodes owing to their layered or tunneled frameworks, which accommodate reversible Zn2+ (de)intercalation with diffusion coefficients superior to conventional vanadium oxides. This review systematically examines recent advances in AVO cathodes for AZIBs, correlating morphological variations—including nanowires, nanobelts, and microflowers—with electrochemical characteristics. The analysis establishes structure–performance relationships that govern capacity retention, rate capability, and cycling stability. Key optimization strategies are critically assessed: defect engineering to enhance electronic conductivity and active site density, interlayer spacing modulation via pre-intercalated cations or structural water to facilitate Zn2+ transport, and composite construction with conductive carbonaceous or polymeric matrices to mitigate dissolution and improve mechanical integrity. Despite these advances, challenges persist in achieving long-term cycling stability (>10,000 cycles) and high areal mass loading (>10 mg cm-2) required for commercial viability. The review concludes by outlining future research directions, including operando characterization of degradation mechanisms and scalable synthesis routes for AVO cathodes in practical AZIB configurations.
Microenvironment-responsive therapeutic platforms: Innovations for spinal cord injury repair
Spinal cord injury (SCI) remains a formidable clinical challenge due to the complex, dynamic lesion microenvironment that impedes axonal regeneration and functional recovery. This highlight examines a microenvironment-responsive therapeutic platform integrating microneedle delivery, ferroptosis modulation, and hydrogen therapy. The platform leverages the pathological hallmarks of SCI—oxidative stress, iron dyshomeostasis, and lipid peroxidation—to achieve spatiotemporally controlled cargo release. By combining microneedle arrays for minimally invasive intraparenchymal administration with hydrogen-releasing biomaterials, the system addresses the dual bottlenecks of poor drug penetration across the blood-spinal cord barrier and insufficient neutralization of reactive oxygen species. Ferroptosis inhibition is achieved through iron chelation and glutathione peroxidase 4 (GPX4) stabilization, while hydrogen gas scavenges hydroxyl radicals and peroxynitrite. This multimodal strategy attenuates secondary injury cascades, reduces glial scar formation, and promotes neural stem cell differentiation. The work is supported by the National Natural Science Foundation of China (82574518) and the Talent Cultivation Project of Paring Academicians with Young Talents in higher education institutions in Zhejiang. The authors declare no conflict of interest. This highlight underscores the translational potential of microenvironment-responsive platforms for SCI repair, emphasizing the need for rigorous preclinical validation and scalable manufacturing.
Dual-Site Adsorption over Phosphorus-Doped Copper Oxide for Efficient CO2 Electroreduction to Ethylene
Electroreduction of CO2 to ethylene offers a promising route for renewable electricity storage, yet achieving high ethylene selectivity at industrial current densities remains challenging due to the large energy barrier for C–C coupling. Here, we report a “MOF-assisted in situ doping” strategy to introduce the oxophilic nonmetal phosphorus (P) into the copper oxide (CuO) lattice, constructing a localized Cu–P dual-site adsorption configuration for the key *OCCHO intermediate. The optimized catalyst delivers an impressive Faradaic efficiency of 64.6% for ethylene with a partial current density of 646 mA cm-2. Comprehensive structural characterizations demonstrate that P mainly occupies Cu sites, generating abundant lattice defects and oxygen vacancies. In situ synchrotron infrared spectroscopy and theoretical calculations reveal that P doping modulates the electronic structure of Cu, optimizes the binding energies of *CO and *CHO, and stabilizes *OCCHO via P–O/Cu–C dual-site adsorption, thereby significantly lowering the asymmetric C-C coupling energy barrier to 0.74 eV. This work highlights a dual-site microenvironment regulation strategy for CO2-to-ethylene electroreduction.
Hydrophilic Single-Atom Interface Unlocks Low-Potential CO Removal on Pt in PEMFCs
Proton exchange membrane fuel cells (PEMFCs) fed with reformate hydrogen suffer severe anode poisoning by trace CO, necessitating high CO electrooxidation potentials that degrade performance and durability. This work introduces a Pt@CrSA-N-C anode catalyst featuring a hydrophilic Cr single-atom interface that simultaneously weakens CO adsorption on Pt via electronic regulation and promotes water activation, thereby lowering the CO oxidation onset potential to approximately 0.13 V vs. RHE. The onset potential was determined by two independent methods: the first potential at which the background-corrected current exceeds 0 mA cm-2 during CO oxidation reaction tests in a three-electrode system, and the potential at which the forward scan current exceeds the N2 background current in CO-stripping voltammetry. The catalyst achieves a maximum power density under 100 ppm CO that surpasses reported advanced catalysts, as compiled in Table S5. Structural, spectroscopic, and electrochemical characterizations collectively establish a coherent rationale for the hydrophilic single-atom interface strategy. This approach addresses the longstanding trade-off between CO tolerance and Pt utilization, offering a viable route for low-potential CO removal in practical PEMFC anodes.
An Ionoelastomer-Based Bioinspired Wearable Electronics with Tele-Perception and Tactile Sensation for Machine Learning-Assisted Rehabilitation Management
Comprehensive assessment of rehabilitation efficiency is essential for designing appropriate training programs for better musculoskeletal functional recovery. Existing contact-receptor-dependent rehabilitation assessment systems mostly focus on assessing the restoration of muscle function by evaluating grip strength or joint flexion angle; however, parameters reflecting neuromuscular synergistic function are always overlooked. Herein, we develop an ionoelastomer-based soft artificial electroreceptor (SAER) that integrates tele-perception and tactile sensation to track the rehabilitation process, collecting signals related to approaching speed and grip strength sequentially. The SAER uses polyurethane ionoelastomer incorporated with quasi-solid conductive salt as the electric field receptor, and is integrated on a rehabilitation-training ball after assembly to establish an untethered detection device; this enables the remote capture of hand approaching parameter within a 9 cm range, followed by the quantification of grip strength when contacting and grasping. Furthermore, a data-driven assessment system is established by integrating machine learning, which accurately classifies rehabilitation efficiency into six levels; it supports for rehabilitation evaluation and training programs adjustment. Overall, the SAER-based rehabilitation management system establishes a paradigm that synergistically evaluating parameters corresponding to neuromuscular functional restoration and holds strong potential for home-based active rehabilitation for minimizing dependence on frequent clinical supervision.
Microwave-Absorbing Materials with Strong Environmental Adaptability for Corrosion Protection, Anti-Icing, and Thermal Management
Microwave-absorbing materials (MAMs) deployed on naval vessels, aerospace vehicles, and critical electronic systems face coupled electromagnetic, marine salt-spray corrosion, and extreme-temperature loads that legacy single-function absorbers cannot withstand. This review consolidates progress on three environmentally adaptive MAM classes: corrosion-protective, anti-icing, and thermal-management absorbers. The electromagnetic loss and impedance-matching fundamentals are first established, then the synergistic mechanisms, design strategies, and characterization protocols for each class are examined against representative material systems and their measured performance. The analysis identifies a shared design logic—multiscale hierarchical architecture, interfacial polarization engineering, and multifunctional phase integration—while distinguishing the divergent protection mechanisms: barrier and passivation effects for corrosion, surface-energy and latent-heat regulation for anti-icing, and phonon–electron transport decoupling for thermal management. Persistent bottlenecks include the trade-off between impedance matching and protective-layer density, the absence of standardized coupled-field test protocols, and the scarcity of long-term salt-spray and thermal-cycling durability data. Future directions are delineated: intelligent self-adaptive absorbers, multiphysics-coupled simulation frameworks, and environmentally benign multifunctional integration. The review provides a theoretical and technical basis for the design, construction, and engineering scale-up of next-generation high-performance absorbers for aerospace, electronic, and marine equipment.