O<sub>2</sub>-Accessible Fe-N<sub>4</sub> Active Site Density Boosts Efficient Oxygen Reduction to Fuel-Cell Level.

Zhang, Tianyu; Liang, Chen; Sun, Shilun; Xi, Shibo; Zhuang, Zhongbin; Yuan, Jinliang; Guo, Zheng Xiao; Liu, Junfeng · Adv Mater · 2026

basic_science · Level V

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Abstract

Not all sites with intrinsic activity show efficacy in practical catalysis due to inaccessibility or diffusion limitation, necessitating rational design of well-connected hierarchical nanostructures to guarantee accessibility. Herein, the case is thoroughly investigated by way of atomically dispersed Fe-NC catalysts for the dominant O<sub>2</sub> gas-consuming reduction (ORR). A pH-dependent nanostructure manipulation strategy was developed to form solid, yolk-shell, and hollow Fe-NC structures with similar overall density of quasi-homogeneous Fe-N<sub>4</sub> sites, providing a comparative platform to investigate O<sub>2</sub> mass transport during ORR. Despite similar Fe loading, y-Fe/NC structures achieve optimized O<sub>2</sub>-accessible active site density (ASD) due to fine-tuned porosity and connectivity for sufficient O<sub>2</sub> accessibility. This observation is re-affirmed by the observation of a relatively high j<sub>d</sub> for the y-Fe/NC, which exceeds the theoretical value of a laminar flow pattern. This can be attributed to the increased O<sub>2</sub>-accessible ASD, originated from the local recirculation effect induced by the unique structure. Consequently, the y-Fe/NC exhibits half-wave potential of 0.82 V and j<sub>d</sub> of 7.66 mA cm<sup>-2</sup>, outperforming counterparts and state-of-the-art catalysts. Moreover, the optimized y-Fe/NC remains effective in fuel cell with power density of 1.03 W cm<sup>-2</sup>, demonstrating the essential roles of rationally designed nanostructures.