Stability of cathode catalyst support material is one of the big challenges of polymer electrolyte membrane fuel cells (PEMFC) for long term applications. Traditional carbon black (CB) supports are not stable enough to prevent oxidation to CO2 under fuel cell operating conditions. The feasibility of a graphitized carbon (GC) as a cathode catalyst support for low temperature PEMFC is investigated herein. GC and CB supported Pt electrocatalysts were prepared via an already developed polyol process. The physical characterization of the prepared catalysts was performed using transmission electron microscope (TEM), X-ray Powder Diffraction (XRD) and inductively coupled plasma optical emission spectrometry (ICP-OES) analysis, and their electrochemical characterizations were conducted via cyclic voltammetry(CV), rotating disk electrode (RDE) and potential cycling, and eventually, the catalysts were processed using membrane electrode assemblies (MEA) for single cell performance tests. Electrochemical impedance spectroscopy (EIS) and scanning electrochemical microscopy (SEM) have been used as MEA diagonostic tools. GC showed superior stability over CB in acid electrolyte under potential conditions. Single cell MEA performance of the GC-supported catalyst is comparable with the CB-supported catalyst. A correlation of MEA performance of the supported catalysts of different Brunauer–Emmett–Teller (BET) surface areas with the ionomer content was also established. GC was identified as a promising candidate for catalyst support in terms of both of the stability and the performance of fuel cell.

Durability of catalyst support materials is one of the big challenges for long‐term fuel cell operation. The performance stabilities of stabilized carbons as cathode catalyst supports for polymer electrolyte membrane fuel cells (PEMFCs) are investigated. Homemade platinum (Pt) electrocatalysts are prepared on stabilized carbons and a traditional carbon black support. Subsequently, the characterization results of homemade catalysts are compared with a commercial catalyst. The characterization tools such as the measurement of electrochemical active surface areas (ECSAs), oxygen reduction reaction (ORR) activities, durability of both the Pt and the supports, and eventually membrane electrode assembly (MEA) single cell tests are implemented herein. The stabilized carbon supported catalysts show comparable ORR activities as well as improved corrosion resistance in terms of ECSA survival rates under accelerated stress conditions compared with the conventional supported catalysts. In addition, the dependency of MEA performances on the ionomer‐to‐carbon ratio on the catalyst layers is established.

Performance of a low temperature polymer electrolyte membrane fuel cell (PEMFC) is highly dependent on the kind of catalysts, catalyst supports, ionomer amount on the catalyst layers (CL), membrane types and operating conditions. In this work, we investigated the influence of membrane types and CL compositions on MEA performance. MEA performance increases under all practically relevant load conditions with reduction of the membrane thickness from 50 to 15 μm, however further decrease in membrane thickness from 15 to 10 μm leads to reduction in cell voltage at high current loads. A thick anode CL is found to be beneficial under wet operating conditions assuming more pore space is provided to accommodate liquid water, whereas under dry operating conditions, an intermediate thickness of the anode CL is beneficial. When studying the impact of catalyst layer thickness, too thin a catalyst layer again shows reduced performance due to increased ohmic resistance ruled out the performance of the MEAs which have identical Pt crystallite sizes on the cathode CLs i. e. the thinnest the cathode CL, the highest the voltage were achieved at a defined current load. Adaptation of the operating conditions is highly anticipated to achieve the highest MEA performance.

In this work, we investigated the influence of catalyst supports, particularly Brunauer, Emmett, and Teller (BET) surface area of the catalyst support materials, on membrane electrode assembly (MEA) performance. Keeping the anode catalyst layer (CL), membrane, Pt loading, and operating condition unchanged, we prepared cathode CLs using catalysts of identical Pt content (30 wt% Pt) which were supported on carbon black materials having different BET surface areas. We observed optimum cell voltage at high current load when using cathode catalyst layers prepared from catalysts supported on carbons having medium-BET surface area. High-BET surface area supports, although beneficial at low current density as well as low-BET surface area supports, led to increased voltage losses at high current load due to mass transport limitations which can be explained by the electrochemically active surface area available and water management in the catalyst layer.

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