Abstract The development of high-performance, durable catalysts for polymer electrolyte membrane fuel cells (PEMFCs) is crucial to the widespread adoption of hydrogen technologies. In this context, three commercial carbon blacks (Regal 330, Vulcan XC 72R, Black Pearl 2000), each with varying surface areas and physical properties, were heat-treated at specific temperatures (1400, 1000, 1200 °C) and then used as support materials for PtCo nanoparticles (NPs). The prepared catalysts were characterized by ICP-MS, TEM, XRD, XPS (Pt 4f, Co 2p), zeta potential, contact angle, and topography analysis. The electrochemical activities of the catalysts were evaluated using CV and LSV in a three-electrode system. PEMFC performance was tested in a single-cell station, and catalyst resistance was determined by EIS. The electrochemical surface areas (ECSAs) of the catalysts are 10.5, 16.3, and 27.5 m 2 g − 1 for PtCo/R-14, PtCo/V-10, and PtCo/BP-12, in parallel with the increase in the surface areas of carbon blacks. In the LSV analysis, PtCo/V-10 achieved the best current density plateau and the highest limiting current density (-2.298 mA cm − 2 , @1600 rpm). In the performance evaluations of PEMFCs conducted at varied retention potentials (0.6 V/0.1 V), the catalysts PtCo/R-14, PtCo/V-10, and PtCo/BP-12 yielded the following current density values: 257.6/322.4, 281.6/384.4, and 95.5/156.9 mA cm − 2 (@0.6 V), respectively. Notably, the PtCo/V-10 catalyst exhibited the highest performance among the tested catalysts. Following 1000 aging cycles, the PtCo/V-10 and the commercial Tanaka catalyst experienced current density loss of 7.26% and 58.35%, respectively. Overall, the PtCo/V-10 catalyst demonstrated the best balance of performance and durability. Graphical Abstract
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