Preliminary
testing of fuel cell catalysts in a model laboratory
environment is an essential step in the technology readiness level
progression of material candidates toward the commercial device. However,
in the case of platinum alloy catalysts for the oxygen reduction reaction
(ORR) in proton exchange membrane fuel cells (PEMFCs), there is no
consensus on the protocol employed for catalyst conditioning (activation
or break-in), leading to important discrepancies in the literature.
Here, the effects of electrochemical conditioning on the PtNi nanocatalyst
structure, chemical composition, and performance for the ORR are investigated
using operando high-energy X-ray diffraction in both the liquid-electrolyte
and solid-electrolyte X-ray transparent PEMFCs, online inductively
coupled plasma mass spectrometry, and the rotating disk electrode
(RDE) techniques, respectively. Our results show that for PtNi/C materials,
the cost in ORR performance associated to complete surface stabilization
at the potential of the ORR can be dramatic but can also be mitigated
by adjusting the initial chemistry and structure of the catalyst.
Overall, this study reveals how uncomplete catalyst conditioning in
the RDE leads to highly erroneous conclusions regarding its performance
and stability to be possibly found in a realistic PEMFC device and
proposes simple strategies to close this gap.