3D-Graphene supports for palladium nanoparticles: Effect of micro/macropores on oxygen electroreduction in Anion Exchange Membrane Fuel Cells

Hierarchically structured 3D-Graphene nanosheets as supports for palladium nanoparticles (Pd/3D-GNS) were fabricated using the Sacrificial Support Method. The pore size distribution of the 3D-GNS supports were tuned by utilizing smaller and larger sized sacrificial silica templates, EH5 and L90. Using a combination of Scanning Electron Microscopy (SEM), N₂ sorption and Rotating Ring Disc Electrode (RRDE) technique, it was demonstrated that the EH5 and L90 modified 3D-GNS supports had higher percentage of micro- (<2 nm) and macropores (>50 nm), respectively. The templated pores also played a role in enhancing the oxygen reduction reaction (ORR) as well as membrane electrode assembly (MEA) performance of the Pd nanoparticles in comparison to non-porous 2D-GNS supports. Particularly, incorporation of micropores increased peroxide generation at higher potentials whereas presence of macropores increased both limiting current densities and reduce peroxide yields. Integration of the Pd/GNS nanocomposites into a H_2/O₂ fed Anion Exchange Membrane Fuel Cell (AEMFC) operating at 60°C also demonstrated the effect of modified porosity on concentration polarization or transport losses at high current densities. This strategy for the tunable synthesis of hierarchically 3D porous graphitized supports offers a platform for developing morphologically modified nanomaterials for energy conversion.