Ultrathin urchin-like PdPtCu alloys anchored CeO2 nanosheets for efficient methanol oxidation

Abstract

Platinum-based catalysts, particularly Pt/C, are widely employed in direct methanol fuel cells (DMFCs); however, their practical deployment is hindered by severe drawbacks, including carbon support corrosion and the high cost of Pt, which collectively compromise long-term durability and economic feasibility. To overcome these limitations, we present the design of an ultrathin, urchin-like PdPtCu ternary alloy supported on CeO2 nanosheets, specifically engineered to enhance both the activity and stability of the methanol oxidation reaction (MOR). A central innovation of this work lies in the employment of a CuO-CeO2 composite support, which enables efficient incorporation of copper via an acid-mediated ligand exchange process-addressing the inherent challenge of immobilizing metallic species on oxide surfaces. The incorporation of CuO facilitates the oxidative activation of copper species, while CeO2 contributes structural robustness and redox-active sites that promote intermediate removal during MOR. The resulting PdPtCu-CeO2 nanostructures exhibit a high surface area and unique urchin-like morphology, both of which contribute to markedly enhanced electrochemical performance. Compared to commercial Pt/C, the PdPtCu-CeO2 catalyst demonstrates approximately threefold enhancements in both mass and specific activities, along with excellent long-term durability as confirmed by chronoamperometric measurements. This work study highlights the promise of oxide-derived hybrid supports and multi-metallic nanostructures for advancing cost-effective and durable electrocatalysts for DMFC applications, thereby advancing the pursuit of next-generation, carbon-free catalyst platforms. (c) 2025 Published by Elsevier Ltd on behalf of The editorial office of Journal of Materials Science & Technology.