  A new dual plasma coating process to produce platinum-free catalysts for the
oxygen reduction reaction in a fuel cell is introduced. The catalysts thus
produced were analysed with various methods. Electrochemical characterisation
was carried out by cyclic voltammetry, rotating ring- and rotating ring-disk
electrode. The surface porosity of the different catalysts thus obtained was
characterised with the nitrogen gas adsorption technique and scanning electron
microscopy was used to determine the growth mechanisms of the films. It is
shown that catalytically active compounds can be produced with this dual plasma
process. Furthermore, the catalytic activity can be varied significantly by
changing the plasma process parameters. The amount of H$_2$O$_2$ produced was
calculated and shows that a 2 electron mechanism is predominant. The plasma
coating mechanism does not significantly change the surface BET area and pore
size distribution of the carbon support used. Furthermore, scanning electron
microscopy pictures of the produced films are presented and show the preference
of columnar growth mechanisms. By using different carbons as the support it is
shown that there is a strong dependence of the catalytic activity that is
probably related to the chemical properties of the carbon.
