Pinhole formation in proton exchange membranes (PEM) may be caused by a process of flaw formation and crack propagation within membranes exposed to cyclic hygrothermal loading. Fracture mechanics can be used to characterize the propagation process, which is thought to occur in a slow, time-dependent manner under cyclic loading conditions, and believed to be associated with limited plasticity. The intrinsic fracture energy has been used to characterize the fracture resistance of polymeric material with limited viscoelastic and plastic dissipation, and has been found to be associated with long-term durability of polymeric materials. Insight into this limiting value of fracture energy may be useful in characterizing the durability of proton exchange membranes, including the formation of pinhole defects. In an effort to collect fracture data with limited plasticity, a knife slit test was adapted to measure fracture energies of PEMs, resulting in fracture energies that were two orders of magnitude smaller than those obtained with other fracture test methods. The presence of a sharp knife blade reduces crack tip plasticity, providing fracture energies that may be more representative of the intrinsic fracture energies of the thin membranes. Three commercial PEMs were tested to evaluate their fracture energies (G c ) at temperatures ranging from 40 to 90 C and humidity levels varying from dry to 90% relative humidity (RH). Experiments were also conducted with membrane specimens immersed in water at various temperatures. The time temperature moisture superposition principle was applied to generate fracture energy master curves plotted as a function of reduced cutting rate based on the humidity and temperature conditions of the tests. The shift with respect to temperature and humidity suggests that the slitting process is viscoelastic in nature. Also such shifts were found to be consistent with those obtained from constitutive tests such as stress relaxation. The fracture energy is more sensitive to temperature than on humidity. The master curves converge at the lowest reduced cutting rates, suggesting similar intrinsic fracture energies; but diverge at higher reduced cutting rates to significantly different fracture energies. Although the relationship between G c and ultimate mechanical durability has not been established, the test method may hold promise for investigating and comparing membrane resistance to failure in fuel cell environments.

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The tensile relaxation modulus of a commercially available proton exchange membrane, Nafion® NRE 211, was obtained over a range of humidity levels and temperatures using a commercial dynamic mechanical analyzer (DMA). Hygral stress relaxation master curves were first constructed, followed by a hygrothermal master curve using the time temperature moisture superposition principle. The hygrothermal master curve was fitted using a 10‐term Prony series and validated using longer term stress relaxation tests. To validate the results from the stress relaxation experiments, short and long‐term creep compliance was converted into stress relaxation modulus using a well‐known viscoelastic conversion formula, and compared with the relaxation modulus obtained under identical conditions. Good agreement was found between the two datasets. It was evident that relaxation data at 2% RH at the test temperatures was not superposable with the master curves obtained at higher relative humidity (10% < RH < 90%) at the temperature range 70 °C < T < 90 °C. It was observed that the longer term relaxation modulus under humid conditions matched well with the hygrothermal master curve; however, the longer term relaxation modulus under dry conditions was significantly higher than the relaxation master curve obtained under dry conditions, raising the possibility of a physical aging process in the ionomer and/or irreversible morphological changes in the membrane under dry conditions.

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