Core-shell Fe/Fe3C heterostructure@carbon layers anchored on N-doped porous carbon for boosting oxygen reduction reaction

It is still challenging but crucial to plumb non-noble metal-based oxygen reduction reaction (ORR) catalysts with comparable or better performance than benchmark Pt/C catalysts. Herein, we proffer an unconventional core-shell-structured iron-based heterostructure electrocatalyst constructed by a Fe/Fe3C heterostructure nanoparticle core wrapped by a graphitic shell embedded on a conductive N-doped mesoporous graphite skeleton (Fe/Fe3C@NC) via facile pyrolysis of MIL-53(Fe) (MIL = Matérial Institute Lavoisier) and melamine. The Fe/Fe3C@NC catalyst delivers more positive half-wave potential (E1/2) of 0.86 V and a low Tafel slope of 56 mV dec−1 for ORR, outpacing the benchmark Pt/C catalyst, and it also shows remarkable long-term durability and excellent methanol tolerance. The marvelous ORR behaviors can be attributed to its distinctive morphologic structure: the heterostructure can enhance intrinsic ORR activity; the core-shell nanostructure can enhance ORR activities through unique electron transfer between iron species and their conductive carbon shells, which can also act as protective barriers to ensure long-term stability; the high-content pyridinic-N doping can be used as additional active centers; and the abundant mesopores facilitate the diffusion of electrolyte, which can further upgrade ORR activities. This study proffers a strategy to design and fabricate non-noble catalysts with well-designed nanoarchitecture and high catalytic activity.