Researchers develop durable platinum-cobalt fuel cell catalyst that could aid data center power needs

Researchers at Washington University in St. Louis have developed a new carbon nanostructure that supports highly durable and efficient platinum-cobalt catalysts for low-temperature fuel cells, offering a potential pathway to power energy-intensive facilities such as data centers. The findings appear in a paper published August 6, 2026, in Nature Nanotechnology (nature.com).

The rapid growth of data centers is increasing electricity demand. According to the Electric Power Research Institute, these facilities could account for as much as 9% of annual U.S. electricity generation by 2030, up from about 4% in 2023 (epri.com; source.washu.edu). Fuel cells, which convert hydrogen and oxygen into electricity, water, and heat, could enable facilities to generate power on-site and reduce grid strain, said lead researcher Gang Wu, the Elvera and William R. Stuckenberg Professor in the McKelvey School of Engineering (source.washu.edu).

“If a data center is able to supply its electricity itself by using a fuel cell, it would directly convert hydrogen and other fuels into the electricity, reducing the burden on the energy grid,” Wu said in a university release (source.washu.edu).

Catalysts are essential for efficient fuel cell operation, but designing ones that combine high activity with long-term durability while minimizing use of costly platinum has proven difficult. Platinum nanoparticles increase surface area for reactions, allowing loadings below one-quarter of a milligram per square centimeter, yet they can dissolve, migrate, or agglomerate during operation, degrading performance. Platinum intermetallic catalysts, such as ordered platinum-cobalt (PtCo), offer better activity and stability than conventional alloys, but forming the ordered atomic structure typically requires high annealing temperatures that cause nanoparticles to clump (sciencedaily.com; source.washu.edu).

Wu’s team, with collaborators from Brookhaven National Laboratory, Lawrence Berkeley National Laboratory, Northeastern University, and the University of Pittsburgh, addressed this trade-off with a radial nanochannel-array carbon sphere (RNCS) support. The material features porous, hollow carbon spheres with ordered radial nanochannels, high porosity, and surface area. This structure confines and evenly disperses dense PtCo intermetallic nanoparticles, enabling annealing at 1,000°C—high enough for a highly ordered L1₀ structure (over 80% ordering)—while keeping particles smaller than 5 nanometers and well-dispersed, even at industry-preferred high platinum contents around 40 weight percent (nature.com; engineering.washu.edu).

In testing, the catalyst retained 85% of its performance after 150,000 severe voltage cycles, estimated as equivalent to roughly 25,000 hours of operation, and delivered strong current densities under heavy-duty conditions. The open channels also improve ionomer distribution and transport of protons, oxygen, and water through the electrode (source.washu.edu; nature.com). The abstract reports retention of 82.5% performance after the accelerated stress test alongside a current density of 2.12 A cm⁻² at 0.70 V (nature.com).

“Our strategy is using this new carbon nanostructure to synthesize platinum cobalt intermetallic nanoparticles that can reduce precious metal content and enhance activity and stability,” Wu said. The open structure “helps the ion-containing material... spread evenly and makes it easier for protons, oxygen and water to move through the electrode... [showing] best-in-class performance and long-lasting durability” (source.washu.edu).

Wu has filed a patent through the WashU Office of Technology Management. Funding came from Washington University in St. Louis. Further development and industry collaboration will be needed to advance the technology for practical applications in data centers, vehicles, and other uses (source.washu.edu).