Plasma synthesis ultra-thin carbon coated PtFe alloys on N-doped graphene-CNT composite for methanol electrooxidation

The methanol oxidation reaction (MOR) remains constrained by the inadequate activity and durability of conventional Pt-based catalysts, particularly across varying pH environments. We present a plasma-tailored synthesis strategy to construct ordered PtFe alloy nanocatalysts anchored on N-doped graphene-carbon nanotube hybrids (PtFe@NGCNT). The synergistic effects of plasma-enhanced alloying and conductive 3D carbon architecture yield ultrafine PtFe nanoparticles (2.13 nm) with protective N-carbon encapsulation. This dual-phase configuration endows PtFe@NGCNT with superior pH-adaptive MOR performance: In acidic media, specific and mass activities reach 2.29 mA/cm² and 2524 mA/mg Pt , surpassing commercial Pt/C by 4.67 and 9.86 times respectively. Alkaline performance further escalates to 13.28 mA/cm² and 6602 mA/mg Pt , exceeding commercial Pt/C by 3.61 and 3.74 times. The catalyst demonstrates remarkable durability after long-term chronoamperometry test and 1000-cycle cyclic voltammetry scanning, attributed to plasma-induced defect engineering in the carbon matrix. This work establishes a universal plasma-engineering paradigm for creating robust, pH-versatile electrocatalysts, propelling the development of next-generation direct methanol fuel cells.