General Strategy for Synthesis of Ordered Pt₃ M Intermetallics with Ultrasmall Particle Size

Controllable synthesis of atomically ordered intermetallic nanoparticles (NPs) is crucial to obtain superior electrocatalytic performance for fuel cell reactions, but still remains arduous. Herein, we demonstrate a novel and general hydrogel-freeze drying strategy for the synthesis of reduced graphene oxide (rGO) supported Pt₃ M (M=Mn, Cr, Fe, Co, etc.) intermetallic NPs (Pt₃ M/rGO-HF) with ultrasmall particle size (about 3 nm) and dramatic monodispersity. The formation of hydrogel prevents the aggregation of graphene oxide and significantly promotes their excellent dispersion, while a freeze-drying can retain the hydrogel derived three-dimensionally (3D) porous structure and immobilize the metal precursors with defined atomic ratio on GO support during solvent sublimation, which is not afforded by traditional oven drying. The subsequent annealing process produces rGO supported ultrasmall ordered Pt₃ M intermetallic NPs (≈3 nm) due to confinement effect of 3D porous structure. Such Pt₃ M intermetallic NPs exhibit the smallest particle size among the reported ordered Pt-based intermetallic catalysts. A detailed study of the synthesis of ordered intermetallic Pt₃ Mn/rGO catalyst is provided as an example of a generally applicable method. This study provides an economical and scalable route for the controlled synthesis of Pt-based intermetallic catalysts, which can pave a way for the commercialization of fuel cell technologies.