In our recent publication in Catal, we report the design and synthesis of shape-controlled CuNi@Pt-Cu core–shell nano-octahedra that deliver a significant advancement in the electrochemical oxidation of formic acid (FAOR)—a key reaction in direct formic acid fuel cells (DFAFCs), which are increasingly recognized as promising candidates for portable and sustainable energy technologies.

Through precise control of synthesis conditions—including elevated temperature (240 °C), rapid thermal ramping (12 °C/min), and gradual Pt precursor injection—we achieved sharp-edged nano-octahedra with (111)-facet-dominated surfaces and a Pt-Cu alloy shell. These structural features synergistically enhance both catalytic activity and long-term durability.

Synthesis highlights:

• Seed-mediated colloidal synthesis (two-pot method) with morphology control
• Sharp-edged core@shell nano-octahedra with narrow size-distribution
• Controlled deposition of uniform layers with sub-nanometer precision

Performance highlights:

• ~5.75× higher specific activity than commercial Pt/C
• ~2.09× higher mass activity
• Only ~17% activity loss after 1-hour durability testing

Industry impact:

These results demonstrate that the nano-octahedra not only outperform conventional catalysts but also offer a platinum-efficient and scalable solution for DFAFCs. By reducing noble metal consumption while maintaining high performance, this work contributes to the development of cost-effective, durable fuel cell systems suitable for real-world applications in clean energy, backup power, and mobile electronics.

Authors:

Can Li, Xiaobo Chen, Lihua Zhang, Bo Zhao, Coby Woodver-Frost, Prabhu Bharathan, Anna Dennett, Guangwen Zhou, and Jiye Fang

Affiliations:

State University of New York at Binghamton, Brookhaven National Laboratory, and Texas Tech University
*Corresponding author: Jiye Fang (jfang@binghamton.edu )