Surface Facet Engineering in Nanoporous Gold for Low-Loading Catalysts in Aluminum–Air Batteries

The performance of metal-air batteries and fuel cells depends on the speed and efficiency of electrochemical oxygen reduction reactions at the cathode, which can be improved by engineering the atomic arrangement of cathode catalysts. It is, however, difficult to improve upon the performance of platinum nanoparticles in alkaline electrolytes with low-loading catalysts that can be manufactured at scale. Here, the authors synthesized nanoporous gold catalysts with increased (100) surface facets using electrochemical dealloying in sodium citrate surfactant electrolytes. These modified nanoporous gold catalysts achieved an 8% higher operating voltage and 30% greater power density in aluminum-air batteries over traditionally prepared nanoporous gold, and their performance was superior to commercial platinum nanoparticle electrodes at a 10 times lower mass loading. The authors used rotation disc electrode studies, backscattering of electrons, and underpotential deposition to show that the increased (100) facets improved the catalytic activity of citrate dealloyed nanoporous gold compared to conventional nanoporous gold. The citrate dealloyed samples also had the highest stability and least concentration of steps and kinks. The developed synthesis and characterization techniques will enable the design and synthesis of metal nanostructured catalysts with controlled facets for low-cost and mass production of metal-air battery cathodes.