Polymer electrolyte fuel cells (PEFCs) are a promising replacement for the fossil fuel–dependent automotive and energy sectors. They have become increasingly commercialized in the last decade; however, significant limitations on durability and performance limit their commercial uptake. Catalyst layer (CL) design is commonly reported to impact device power density and durability; although, a consensus is rarely reached due to differences in testing conditions, experimental design, and types of data reported. This is further exacerbated by aspects of CL design such as catalyst support, proton conduction, catalyst, fabrication, and morphology, being significantly interdependent; hence, a wider appreciation is required in order to optimize performance, improve durability, and reduce costs. Here, the cutting‐edge research within the field of PEFCs is reviewed, investigating the effect of different manufacturing techniques, electrolyte distribution, support materials, surface chemistries, and total porosity on power density and durability. These are critically appraised from an applied perspective to inform the most relevant and promising pathways to make and test commercially viable cells. This holistic view of the competing aspects of CL design and preparation will facilitate the development of optimized CLs, especially the incorporation of novel catalyst support materials.

Over the last century, X-ray imaging instruments and their accompanying tomographic reconstruction algorithms have developed considerably. With improved tomogram quality and resolution, voxel sizes down to tens of nanometres can now be achieved. Moreover, recent advancements in readily accessible lab-based X-ray computed tomography (X-ray CT) instruments have produced spatial resolutions comparable to specialist synchrotron facilities. Electrochemical energy conversion devices, such as fuel cells and batteries, have inherently complex electrode microstructures to achieve competitive power delivery for consideration as replacements for conventional sources. With resolution capabilities spanning tens of microns to tens of nanometres, X-ray CT has become widely employed in the three-dimensional (3D) characterisation of electrochemical materials. The ability to perform multiscale imaging has enabled characterisation from system-down to particle-level, with the ability to resolve critical features within device microstructures. X-ray characterisation presents a favourable alternative to other 3D methods such as focused ion beam scanning electron microscopy, due to its non-destructive nature, which allows four-dimensional (4D) studies, three spatial dimensions plus time, linking structural dynamics to device performance and lifetime. X-ray CT has accelerated research from fundamental understanding of the links between cell structure and performance, to the improvement in manufacturing and scale-up of full electrochemical cells. Furthermore, this has aided in the mitigation of degradation and celllevel failures such as thermal runaway. This review presents recent developments in the use of X-ray CT as a characterisation method and its role in the advancement of electrochemical materials engineering.

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Lithium sulfur (Li–S) batteries have great potential as a successor to Li-ion batteries, but their commercialization has been complicated by a multitude of issues stemming from their complex multiphase chemistry. In situ X-ray tomography investigations enable direct observations to be made about a battery, providing unprecedented insight into the microstructural evolution of the sulfur cathode and shedding light on the reaction kinetics of the sulfur phase. Here, for the first time, the morphology of a sulfur cathode was visualized in 3D as a function of state of charge at high temporal and spatial resolution. While elemental sulfur was originally well-dispersed throughout the uncycled cathode, subsequent charging resulted in the formation of sulfur clusters along preferred orthogonal orientations in the cathode. The electrical conductivity of the cathode was found not to be rate-limiting, suggesting the need to optimize the loading of conductive carbon additives. The carbon and binder domain and surrounding bulk pore phase were visualized in the in situ cell, and contrast changes within both phases were successfully extracted. The applications of this technique are not limited to microstructural and morphological characterization, and the volumetric data can serve as a valuable input for true 3D computational modeling of Li–S batteries.