Strategies to improve CO tolerance and corrosion resistance of Pt electrocatalysts for polymer electrolyte membrane fuel cells: Sn-doping of the mixed oxide–carbon composite support

Design of composite support materials based on Sn-doped TiO2 and carbon is one of the strategies to develop corrosion-resistant and CO-tolerant Pt electrocatalysts for polymer electrolyte membrane (PEM) fuel cells. As the synthesis methodology may have crucial influence on the structural and functional properties of the composites, different preparation routes for the novel support materials are explored and compared. Ti(1-x)SnxO2–C (x: 0.1–0.3) composites with different mixed oxide/carbon ratios were prepared by two sol-gel-based synthesis routes, namely (i) the introduction of a Sn precursor after the formation of the TiO2-rutile nuclei on the carbon backbone (route A), and (ii) simultaneous introduction of Ti and Sn precursors, resulting in good mixing of the Sn- and Ti-sol before the addition of the carbon (route B). The bulk and surface microstructure of the composites and the electrocatalysts obtained by their Pt-loading were investigated in detail. The incorporation of tin into the TiO2-rutile unit cell was confirmed by X-ray powder diffraction and Raman spectroscopy; the results indicated doping levels in good accordance with the amount of tin precursor. The advantages of composites and Pt electrocatalysts obtained via synthesis route B were that they do not contain segregated Sn0 or SnO2 phases, have a more homogeneous/uniform mixed oxide distribution over the carbon backbone, and the electrochemically active surface area values (∼60–80 m2/gPt) are twice as high as those of catalysts with similar compositions synthesized by method A. A common feature of the composites prepared by routes A and B was the presence of a tin oxide-rich overlayer identified by X-ray photoelectron spectroscopy. As a consequence, the electrocatalytic behavior of the catalysts was not influenced by the Ti/Sn ratio and was mainly dependent on the synthesis method used in the preparation of composite support materials. Elemental maps confirmed the formation of areas where Pt and the Sn doping element were in atomic proximity to each other, which means a favorable interaction either for the bifunctional mechanism or the electronic ligand effect. An increase in carbon content in composite materials led to an increase in both catalytic activity and long-term stability. The results of electrochemical studies showed that Sn-containing Pt catalysts with a high carbon content (75 wt%) are the most promising for potential use both as an anode and a cathode for PEM fuel cells. [Displ