Abstract: A method for forming a corrosion-resistant catalyst for fuel cell catalyst layers is provided. The method includes a step of depositing a conformal Pt or platinum alloy thin layer on NbO2 substrate particles to form Pt-coated NbO2. The Pt-coated NbO2 particles are then incorporated into a fuel cell catalyst layer.

Abstract: A coated substrate for forming fuel cell catalyst layers includes a plurality of substrate particles, an adhesion layer disposed over the substrate particles, and a precious metal layer disposed over the adhesion layer. The substrate particles may be carbon powders, carbon nanorods, carbon nanotubes and combinations thereof; with a preferred aspect ratio from 10:1 to 25:1. The adhesion layer includes a tungsten metal layer and may be formed into a heterogeneous layer comprising a lattice-interrupting layer interposed between two tungsten metal layers. The lattice-interrupting layer reduces mechanical stress to the adhesion layer with extended thickness that may develop when it experiences changing environments, and can be any layer other than the metal layer, for example, Al2O3, Al, or WOx, where x is 1.5 to 3.0. Characteristically, the coated substrate is used in fuel cell applications such as providing the catalyst particles used in the cathode and/or anode catalyst layers.

Abstract: A method for forming a corrosion-resistant catalyst for fuel cell catalyst layers is provided. The method includes a step of depositing a conformal Pt or platinum alloy thin layer on NbO2 substrate particles to form Pt-coated NbO2. The Pt-coated NbO2 particles are then incorporated into a fuel cell catalyst layer.

Abstract: A coated substrate for forming fuel cell catalyst layers includes a plurality of substrate particles, an adhesion layer disposed over the substrate particles, and a precious metal layer disposed over the adhesion layer. The adhesion layer includes a tungsten metal layer. Characteristically, the coated substrate is used in fuel cell applications such as providing the catalyst particles used in the cathode and/or anode catalyst layers.