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Room-temperature synthesis produces hollow nanodome catalyst, slashing fuel cell costs and extending life

High-performance fuel cell catalyst synthesized at room temperature—no high heat needed
A simplified schematic depicting the formation mechanism of NiPt nanocatalysts with a dome-shaped hollow polycrystalline structure incorporating a Ni3Pt5 intermetallic phase. The process is driven by an ultrasound-assisted borohydride reduction reaction carried out under ambient temperature and pressure conditions. Credit: Korea Institute of Science and Technology (KIST)

Hydrogen fuel cells, which produce electricity with high efficiency and zero greenhouse gas emissions, are gaining attention as a next-generation clean energy technology. However, their commercialization has been limited by performance degradation during prolonged operation and the high cost of catalyst replacement.

These issues stem from the instability of conventional catalysts, which suffer from metal dissolution and particle agglomeration over time, reducing reaction efficiency. To address this, the development of durable, high-performance catalysts that can be produced at low cost has become a critical research goal.

A joint research team led by Dr. Sung Jong Yoo at the Center for Hydrogen and Fuel Cells of the Korea Institute of Science and Technology (KIST), Professor Dong Won Chun of POSTECH, Professor Yongsoo Yang of KAIST, and Professor Haneul Jin of Dongguk University has developed a new technology that enables the synthesis of highly active and durable catalyst at room temperature using a simple ultrasound-assisted method.

The paper is in the journal Advanced Materials.

The newly developed catalyst features platinum and nickel precisely arranged into nanoscale domes with a hollow structure. This design increases the reactive surface area while minimizing catalyst loss, resulting in significantly improved performance.

High-performance fuel cell catalyst synthesized at room temperature—no high heat needed
High-resolution atomic-level analysis revealed a total of 1,534 atoms (591 Ni and 943 Pt) within the NiPt-SP nanocatalyst. Local atomic arrangement analysis demonstrated that a significant portion of atoms within the crystal grains conform to the Ni3Pt5 intermetallic phase, providing direct evidence of atomic ordering within the NiPt-SP nanoparticles. Credit: Korea Institute of Science and Technology (KIST)

Traditionally, creating such precise nanostructures required complex processes at temperatures exceeding 600°C. In contrast, the new method enables atomic rearrangement using just a one-step ultrasound process at room temperature.

The researchers employed an ultrasonic device similar to those used in eyeglass cleaning to naturally guide metal atoms into ordered structures, significantly simplifying the and lowering with enhanced activity and durability.

In half-cell tests designed to measure the intrinsic catalytic activity, the new catalyst showed about seven times higher mass activity compared to commercial catalysts. Even in full-cell tests under practical fuel cell conditions, it maintained a notable lead with about five times higher mass activity.

In durability evaluations conducted according to U.S. Department of Energy (DOE) protocols, the catalyst remained stable for over 42,000 hours—more than 4.2 times the lifespan of currently available commercial catalysts. This breakthrough is expected to reduce replacement intervals and maintenance costs in large-scale fuel cell systems used in trucks, buses, ships, and power plants.

High-performance fuel cell catalyst synthesized at room temperature—no high heat needed
A visual representation of the synthesis process of dome-shaped hollow NiPt nanocatalysts incorporating Ni3Pt5 ordered structures, published as the Back Cover of Advanced Materials. The image illustrates atomic-scale transitions driven by ultrasound at room temperature: from initial random alloy seed formation (Pt-rich) to particle growth, hollow structure formation, and alloying. Continued ultrasound exposure then induces atomic ordering within the particles. Credit: Korea Institute of Science and Technology (KIST)

Catalysts account for over 30% of the total manufacturing cost of fuel cell systems. By extending catalyst lifespan and boosting performance, the new technology significantly enhances the economic viability of hydrogen fuel cells.

The team is currently exploring various transition metal combinations to further expand the technology, while also conducting fuel cell stack-level evaluations and demonstration studies for automotive applications.

Dr. Yoo of KIST stated, "Our catalyst features a unique dome-shaped nanostructure with precisely arranged atoms, resulting in substantial improvements in both activity and durability. Because the process works at room temperature, we believe this technology can play a meaningful role in advancing the commercialization of and achieving carbon neutrality."

More information: Eungjun Lee et al, Suppressing Metal Dissolution in Multi‐Grained Catalysts Through Intragrain Atomic Ordering for Stable Fuel Cells, Advanced Materials (2025).

Journal information: Advanced Materials

Citation: Room-temperature synthesis produces hollow nanodome catalyst, slashing fuel cell costs and extending life (2025, August 8) retrieved 25 September 2025 from /news/2025-08-room-temperature-synthesis-hollow-nanodome.html
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