Highly active robust oxide solid solution electro-catalysts for oxygen reduction reaction for proton exchange membrane fuel cell and direct methanol fuel cell cathodes

The identification and development of novel non-noble metals based electro-catalyst exhibiting excellent electrochemical activity and stability than noble metal electro-catalyst is important for commercial development of proton exchange membrane fuel cells (PEMFCs). Such non-noble electro-catalyst with unique electronic structure and superior electrochemical performance will immensely contribute to lowering the capital cost of PEMFCs. Herein, we have identified solid solution electro-catalysts of WO3 and IrO2 for oxygen reduction reaction (ORR) in PEMFCs exploiting theoretical first principles approaches. The theoretical results were experimentally validated by generation of nanostructured (W1-xIrx)Oy (x = 0.2, 0.3; y = 2.7–2.8) electro-catalysts for ORR. (W0.7Ir0.3)Oy demonstrated ∼43% improved electrochemical activity than Pt/C with similar loading at 0.9 V (vs RHE), respectively. Moreover, single full cell PEMFC study revealed an acceptable ∼81% improved maximum power density for (W0.7Ir0.3)Oy than Pt/C combined with excellent long term stability. These results thus, show the potential of (W0.7Ir0.3)Oy as ORR electro-catalyst for replacing of Pt/C in PEMFCs and direct methanol fuel cells on the additional grounds of superior methanol tolerance. [Display omitted] •(W1−xIrx)Oy studied as ORR electro-catalyst following DFT calculations.•DFT studies validate WO3 electronic structure modification by incorporation of IrO2.•Nanostructured (W1−xIrx)Oy synthesized using wet chemical approach.•(W0.7Ir0.3)Oy shows 43% improved electrochemical performance than Pt/C.•(W0.7Ir0.3)Oy shows excellent electrochemical stability similar to Pt/C.