Abstract: Methods of making catalyst electrodes comprising sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising, respectively in any order, at least Pt and Ir. In some exemplary embodiments, catalyst electrodes described, or made as described, herein are anode catalyst, and in other exemplary embodiments cathode catalyst. Catalysts electrodes are useful, for example, in generating H2 and O2 from water.

Abstract: Membrane electrode assembly comprising oxygen evolution reaction catalyst disposed in gas distribution layer (100, 700) or between gas distribution layer (100, 700 and gas dispersion layer (200, 600). Membrane electrode assemblies described herein are useful, for example, in electrochemical devices such as a fuel cell.

Abstract: Methods of making catalyst electrodes comprising sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising, respectively in any order, at least Pt and Ir. In some exemplary embodiments, catalyst electrodes described, or made as described, herein are anode catalyst, and in other exemplary embodiments cathode catalyst. Catalysts electrodes are useful, for example, in generating H2 and O2 from water.

Abstract: Membrane electrode assembly comprising oxygen evolution reaction catalyst disposed in gas distribution layer (100, 700) or between gas distribution layer (100, 700 and gas dispersion layer (200, 600). Membrane electrode assemblies described herein are useful, for example, in electrochemical devices such as a fuel cell.

Abstract: Nanostructured thin film catalysts which may be useful as fuel cell catalysts are provided, the catalyst materials including intermixed inorganic materials. In some embodiments the nanostructured thin film catalysts may include catalyst materials according to the formula PtxM(1-x) where x is between 0.3 and 0.9 and M is Nb, Bi, Re, Hf, Cu or Zr. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaCobMc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and M is Au, Zr, or Ir. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaTibQc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and Q is C or B.

Abstract: Fuel cell anodes comprising (a) a catalyst comprising Pt, (b) an oxygen evolution reaction catalyst, and (c) at least one of Au, a refractory metal (e.g., at least one of Hf, Nb, Os, Re, Rh, Ta, Ti, W, or Zr), a refractory metal oxide, a refractory metal boride, a refractory metal carbide, a refractory metal nitride, or a refractory metal silicide. The fuel cell anodes are useful in fuel cells.

Abstract: This invention relates to non-precious metal fuel cell cathode catalysts, fuel cells that contain these catalysts, and methods of making the same. The fuel cell cathode catalysts are highly nitrogenated carbon materials that can contain a transition metal. The highly nitrogenated carbon materials can be supported on a nanoparticle substrate.

Abstract: In one aspect, the present disclosure describes a first article comprising nanostructured whiskers having a first layer thereon comprising an organometallic compound comprising at least one of Ru or Ir. Optionally, the first layer further comprises an complex comprising at least one of Ru or Ir. Typically, the article includes at least one or more additional layers (e.g., a second layer comprising at least one of metallic Ir, Ir oxide, or Ir hydrated oxide on the first layer). Articles described herein are useful, for example, in fuel cell catalysts (i.e., an anode or cathode catalyst).

Abstract: Methods of making catalyst electrodes comprising sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising, respectively in any order, at least Pt and Ir. In some exemplary embodiments, catalyst electrodes described, or made as described, herein are anode catalyst, and in other exemplary embodiments cathode catalyst. Catalysts electrodes are useful, for example, in generating H2 and O2 from water.

Abstract: Nanostructured thin film catalysts which may be useful as fuel cell catalysts are provided, the catalyst materials including intermixed inorganic materials. In some embodiments the nanostructured thin film catalysts may include catalyst materials according to the formula PtxM(1?x) where x is between 0.3 and 0.9 and M is Nb, Bi, Re, Hf, Cu or Zr. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaCobMc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and M is Au, Zr, or Ir. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaTibQc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and Q is C or B.

Abstract: In some embodiments, the present disclosure provides a fuel cell catalyst having a catalyst surface bearing a non-occluding layer of iridium. In some embodiments, the present disclosure provides a fuel cell catalyst comprising a catalyst surface bearing a sub-monolayer of iridium. In some embodiments, the present disclosure provides a fuel cell catalyst comprising a catalyst surface bearing a layer of iridium having a planar equivalent thickness of between 1 and 100 Angstroms. In some embodiments, the fuel cell catalyst comprises nanostructured elements comprising microstructured support whiskers bearing a thin film of nanoscopic catalyst particles. The layer of iridium typically has a planar equivalent thickness of between 1 and 100 Angstroms and more typically between 5 and 60 Angstroms. The fuel cell catalyst typically comprises no electrically conductive carbon material and typically comprises at least a portion of the iridium in the zero oxidation state.

Abstract: This invention relates to non-precious metal fuel cell cathode catalysts, fuel cells that contain these catalysts, and methods of making the same. The fuel cell cathode catalysts are highly nitrogenated carbon materials that can contain a transition metal. The highly nitrogenated carbon materials can be supported on a nanoparticle substrate.

Abstract: An oxygen-reducing catalyst layer, and a method of making the oxygen-reducing catalyst layer, where the oxygen-reducing catalyst layer includes a catalytic material film disposed on a substrate with the use of physical vapor deposition and thermal treatment. The catalytic material film includes a transition metal that is substantially free of platinum. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

Abstract: A method is provided for making a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles, where the method comprises step a) of vacuum deposition of material from at least a first carbon target in the presence of nitrogen and step b) of vacuum deposition of material from a second target comprising at least one transition metal, the second target comprising no precious metals. In one embodiment, step a) is carried out prior to step b). In another embodiment, steps a) and b) are carried out simultaneously. Typically the deposition steps are carried out in the absence of oxygen. Typically, the transition metal is iron or cobalt, and most typically iron. The present disclosure also provides a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles made according to the present method.

Abstract: Nanostructured thin film catalysts which may be useful as fuel cell catalysts are provided, the catalyst materials including intermixed inorganic materials. In some embodiments the nanostructured thin film catalysts may include catalyst materials according to the formula PtxM(1-x) where x is between 0.3 and 0.9 and M is Nb, Bi, Re, Hf, Cu or Zr. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaCobMc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and M is Au, Zr, or Ir. The nanostructured thin film catalysts may include catalyst materials according to the formula PtaTibQc where a+b+c=1, a is between 0.3 and 0.9, b is greater than 0.05, c is greater than 0.05, and Q is C or B.

Abstract: Methods are provided for making oxygen-reducing catalyst layers, which include simultaneous or sequential stops of physical vapor depositing an oxygen-reducing catalytic material onto a substrate, the catalytic material comprising a transition metal that is substantially free of platinum; and thermally treating the catalytic material. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

Abstract: A fuel cell comprising a membrane electrode assembly, and an IR transmissive window for thermographic analysis of a surface of the membrane electrode assembly is described. The test fuel cell provides a method of monitoring a fuel cell, and capturing a thermographic profile of said fuel cell with an IR detector array, while simultaneously measuring the electrochemical output of the cell, including current, voltages and half cell potentials.

Abstract: In some embodiments, the present disclosure provides a fuel cell catalyst having a catalyst surface bearing a non-occluding layer of iridium. In some embodiments, the present disclosure provides a fuel cell catalyst comprising a catalyst surface bearing a sub-monolayer of iridium. In some embodiments, the present disclosure provides a fuel cell catalyst comprising a catalyst surface bearing a layer of iridium having a planar equivalent thickness of between 1 and 100 Angstroms. In some embodiments, the fuel cell catalyst comprises nanostructured elements comprising microstructured support whiskers bearing a thin film of nanoscopic catalyst particles. The layer of iridium typically has a planar equivalent thickness of between 1 and 100 Angstroms and more typically between 5 and 60 Angstroms. The fuel cell catalyst typically comprises no electrically conductive carbon material and typically comprises at least a portion of the iridium in the zero oxidation state.

Abstract: A fuel cell cathode catalyst is provided comprising nanostructured elements comprising microstructured support whiskers bearing nanoscopic catalyst particles; wherein the catalyst comprises platinum and manganese and at least one other metal selected from the group consisting of Group VIb metals, Group VIIb metals and Group VIIIb metals other than platinum and manganese; wherein the volume ratio of platinum to the sum of all other metals in the catalyst is between about 1 and about 4 and wherein the Mn content is equal to or greater than about 5 micrograms/cm2 areal density. Typically, the volume ratio of manganese to the at least one other metal is between 10:90 and 90:10. Typically, the at least one other metal is Ni or Co. In addition, a fuel cell MBA comprising the present cathode catalyst is provided. In addition, methods of making the present cathode catalyst are provided.

Abstract: A method is provided for making a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles, where the method comprises step a) of vacuum deposition of material from at least a first carbon target in the presence of nitrogen and step b) of vacuum deposition of material from a second target comprising at least one transition metal, the second target comprising no precious metals. In one embodiment, step a) is carried out prior to step b). In another embodiment, steps a) and b) are carried out simultaneously. Typically the deposition steps are carried out in the absence of oxygen. Typically, the transition metal is iron or cobalt, and most typically iron. The present disclosure also provides a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles made according to the present method.