Controlling the Interfacial Environment in the Electrosynthesis of MnO_x Nanostructures for High-Performance Oxygen Reduction/Evolution Electrocatalysis

High-performance, nonprecious metal bifunctional electrocatalysts for the oxygen reduction and evolution reactions (ORR and OER, respectively) are of great importance for rechargeable metal–air batteries and regenerative fuel cells. A comprehensive study based on statistical design of experiments is presented to investigate and optimize the surfactant-assisted structure and the resultant bifunctional ORR/OER activity of anodically deposited manganese oxide (MnO x ) catalysts. Three classes of surfactants are studied: anionic (sodium dodecyl sulfate, SDS), non-ionic ( t -octylphenoxypolyethoxyethanol, Triton X-100), and cationic (cetyltrimethylammonium bromide, CTAB). The adsorption of surfactants has two main effects: increased deposition current density due to higher Mn 2+ and Mn 3+ concentrations at the outer Helmholtz plane (Frumkin effect on the electrodeposition kinetics) and templating of the MnO x nanostructure. CTAB produces MnO x with nanoneedle (1D) morphology, whereas nanospherical- and nanopetal-like morphologies are obtained with SDS and Triton, respectively. The bifunctional performance is assessed based on three criteria: OER/ORR onset potential window (defined at 2 and −2 mA cm –2 ) and separately the ORR and OER mass activities. The best compromise among these three criteria is obtained either with Triton X-100 deposited catalyst composed of MnOOH and Mn 3 O 4 or SDS deposited catalyst containing a combination of α- and β-MnO 2, MnOOH, and Mn 3 O 4 .The interaction effects among the deposition variables (surfactant type and concentration, anode potential, Mn 2+ concentration, and temperature) reveal the optimal strategy for high-activity bifunctional MnO x catalyst synthesis. Mass activities for OER and ORR up to 49 A g –1 (at 1556 mV RHE ) and −1.36 A g –1 (at 656 mV RHE ) are obtained, respectively.