PtTi binary electrocatalysts with low Pt loading at the electrodes have been developed by plasma magnetron co-sputtering method under optimized conditions without significant loss in cell performance. Loading of the electrodes in the range of 0.05–0.40 mg cm⁻² is achieved by controlling sputtering time. Deposition at 0.15 mbar argon pressure leads to the formation of conical nanopillars like structures, which play an essential role in the electrochemical activity, durability and cell performance of the electrocatalysts, offering a high electrochemically active surface area. The best assembled Membrane Electrode Assembly (MEA) i.e. MEA4 with a prepared electrode of five times less PtTi catalysts loading than standard Pt/C exhibits a maximum power density of 0.604 W cm⁻² compared to standard Pt/C electrode with the maximum power density of 0.618 W cm⁻². In addition, nine times high Pt mass-specific and five times high PtTi mass-specific power density have been achieved in comparison to commercial Pt/C electrodes.

Graphical abstract

The energy conversion of PEM fuel cell occurs through HOR and ORR in presence of suitable catalyst(s). High surface area of the catalyst(s) is desirable for better performance of the cell. The best assembled MEA with low loaded co-sputtered PtTi binary catalyst exhibits maximum power density of 0.604 W cm^-2.