Constructing uniform sub-3 nm PtZn intermetallic nanocrystals via atomic layer deposition for fuel cell oxygen reduction

The preparation of ultra-small structurally ordered Pt-based intermetallic nanocrystals (< 3 nm) is still challenging due to the sintering during high temperature ordering. We report a strategy to construct size and distribution controllable Pt-based intermetallic nanocrystals based on ultra-thin metal oxide coating on Pt nanoparticles via atomic layer deposition. The area-selective and thickness controllable metal oxide coatings can not only provide metal atoms for alloying, but also prevent the sintering of Pt nanoparticles during subsequently fast ordering reduction. The prepared uniform PtZn intermetallic nanocrystals with the size of 2.50 +/- 0.65 nm achieve outstanding single-cell performance with the mass activity of 0.48 A mg(Pt)(-1) at 0.9 V and 10.42 % loss of mass activity after 30,000 voltage cycles, which is superior to commercial Pt/C. The enhanced activity and durability is attributed to the decreased binding energy of Pt-oxygen intermediates for weakly polarized surface Pt atoms and suppressed electrochemical Ostwald ripening.