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: 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: Polymer electrolyte membrane (PEM) fuel cell membrane electrode assemblies (MEA's) are provided which have nanostructured thin film (NSTF) catalyst electrodes and additionally a sublayer of dispersed catalyst situated between the NSTF catalyst and the PEM of the MEA.

Abstract: Processes for forming films comprising multiple layers of nanostructured support elements are described. A first layer of nanostructured support elements is formed by depositing a base material on a substrate and annealing. Further growth of the first layer of nanostructures is then inhibited. Additional layers of nanostructured support elements may be grown on the first layer of nanostructures through additional deposition and annealing steps. The multilayer films provide increased surface area and are particularly useful in devices where catalyst activity is related to the surface area available to support catalyst particles.

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 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: This disclosure provides methods of making an enhanced activity nanostructured thin film catalyst by radiation annealing, typically laser annealing, typically under inert atmosphere. Typically the inert gas has a residual oxygen level of 100 ppm. Typically the irradiation has an incident energy fluence of at least 30 mJ/mm2. In some embodiments, the radiation annealing is accomplished by laser annealing. In some embodiments, the nanostructured thin film catalyst is provided on a continuous web.

Abstract: Components that include catalyst layers used in membrane electrode assemblies (MEAs), and methods of making such components are described. The catalyst layers yield more uniform current distributions across the active area of the MEA during operation. The catalyst layers may have a uniform catalyst activity profile of a less active catalyst to achieve more uniform current density over the MEA active area. The catalyst layers may have a variable activity profile, such as an activity profile with a varying slope, to compensate for the inherent nonlinearities of catalyst utilization during operation of an electrochemical fuel cell. Desired variable catalyst activity profiles may be achieved, for example, by varying the catalyst loading across the MEA from inlet to outlet ports or by varying the surface area of the catalyst loading or by varying the surface area of the catalyst support elements.

Abstract: This disclosure provides methods of making an enhanced activity nanostructured thin film catalyst by radiation annealing, typically laser annealing, typically tinder inert atmosphere, Typically the inert gas has a residual oxygen level of 100 ppm. Typically the irradiation has an incident energy fluence of at least 30 mJ/mm2. In some embodiments, the radiation annealing is accomplished by laser annealing. In some embodiments, the nanostructured thin film catalyst is provided on a continuous web.

Abstract: Polymer electrolyte membrane (PEM) fuel cell membrane electrode assemblies (MEA's) are provided which have nanostructured thin film (NSTF) catalyst electrodes and additionally a sublayer of dispersed catalyst situated between the NSTF catalyst and the PEM of the MEA.

Abstract: Components that include catalyst layers used in membrane electrode assemblies (MEAs), and methods of making such components are described. The catalyst layers yield more uniform current distributions across the active area of the MEA during operation. The catalyst layers may have a uniform catalyst activity profile of a less active catalyst to achieve more uniform current density over the MEA active area. The catalyst layers may have a variable activity profile, such as an activity profile with a varying slope, to compensate for the inherent nonlinearities of catalyst utilization during operation of an electrochemical fuel cell. Desired variable catalyst activity profiles may be achieved, for example, by varying the catalyst loading across the MEA from inlet to outlet ports or by varying the surface area of the catalyst loading or by varying the surface area of the catalyst support elements.

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: Components that include catalyst layers used in membrane electrode assemblies (MEAs), and methods of making such components are described. The catalyst layers yield more uniform current distributions across the active area of the MEA during operation. The catalyst layers may have a uniform catalyst activity profile of a less active catalyst to achieve more uniform current density over the MEA active area. The catalyst layers may have a variable activity profile, such as an activity profile with a varying slope, to compensate for the inherent nonlinearities of catalyst utilization during operation of an electrochemical fuel cell. Desired variable catalyst activity profiles may be achieved, for example, by varying the catalyst loading across the MEA from inlet to outlet ports or by varying the surface area of the catalyst loading or by varying the surface area of the catalyst support elements.

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.