Rational Design of NiZnx@CuO Nanoarray Architectures for Electrocatalytic Oxidation of Methanol

Methanol oxidation reaction (MOR) in anodes is one of the significant aspects of direct methanol fuel cells (DMFCs), which also plays a critical role in achieving a carbon-neutral economy. Designing and developing efficient, cost-effective, and durable non-Pt group metal-based methanol oxidation catalysts are highly desired, but a gap still remains. Herein, we report well-defined hierarchical NiZnx@CuO nanoarray architectures as active electrocatalysts for MOR, synthesized by combining thermal oxidation treatment and magnetron sputtering deposition through a brass mesh precursor. After systematically evaluating the electrocatalytic performance of NiZnx@CuO nanoarray catalysts with different preparation conditions, we found that the NiZn1000@CuO (thermally oxidized at 500 °C for 2 h, nominal thickness of the NiZn alloy film is 1000 nm) electrode delivers a high current density of 449.3 mA cm-2 at 0.8 V for MOR in alkaline media as well as excellent operation stability (92% retention after 12 h). These outstanding MOR performances can be attributed to the hierarchical well-defined structure that can not only render abundant active sites and a synergistic effect to enhance the electrocatalytic activity but also can effectively facilitate mass and electron transport. More importantly, we found that partial Zn atoms could leach from the NiZn alloy, resulting in rough surface nanorods, which would further increase the specific surface area. These results indicate that the NiZn1000@CuO nanoarray architecture could be a promising Pt group metal alternative as an efficient, cost-effective, and durable anode catalyst for DMFCs.