Elucidating the Dynamic Nature of Fuel Cell Electrodes as a Function of Conditioning: An ex Situ Material Characterization and in Situ Electrochemical Diagnostic Study

Comprehensive Study on the Electrochemical Evolution, Reaction Kinetics, and Mass Transport at the Anion Exchange Ionomer-Pt Interface for Oxygen Reduction Reaction

Understanding the structure evolution, kinetics, and mass transfer for the oxygen reduction reaction (ORR) at the ionomer-catalyst interface is fundamental for the development of anion exchange membrane fuel cells (AEMFCs). Herein, we investigate the structural evolution of ionomer-Pt interfaces during the activation process of polycrystalline Pt (poly-Pt) electrodes and their ORR kinetics and mass transfer characteristics at steady state. The results suggest the ionomer thickness as a critical factor in determining the Pt surface structure and the flux of the O2 diffusion, which in turn affect the subsequent kinetic and mass transfer of the ORR on ionomer-Pt electrode interfaces. Thicker ionomer film leads to a more severe evolution of electrochemical features during the activation process, likely caused by forming more less-active Pt clusters at the ionomer-Pt interface. Thus, the ORR kinetic activity at the steady state decreases with the increase in ionomer thickness. Concurrently, the thicker ionomer leads to a reduced diffusion flux of O2, culminating in a lower limiting current density for the ORR. Additionally, we calculated the diffusion coefficient and solubility of O2 within the FAA-3 alkaline ionomer film, with a comparative assessment against those in the proton exchange membrane (PEM). These findings offer valuable insights into the ionomer-Pt interface in AEMFCs and their effects on performance.

Unveiling Local Aging Patterns Following Accelerated Stress Testing of High-Performance Polymer Electrolyte Fuel Cells

This study presents an in-depth analysis of heterogeneous aging patterns in membrane electrode assemblies (MEAs) subjected to diverse accelerated stress test (AST) conditions, simulating carbon corrosion (CC AST) and Pt particle size growth in fully humidified (Pt AST-Wet) and underhumidified (Pt AST-Dry) H2/N2 atmospheres. Multimodal characterization techniques are used to focus on heterogeneous aging patterns, primarily examining the variations in current distributions and Pt particle size maps. The findings reveal distinct characteristics of current distributions for all the AST cases, with substantial changes and strong current gradients in the CC AST case, indicative of severe performance degradation. Notably, despite significant differences in Pt particle size growth at the end-of-life (EOL), the Pt AST-Wet and Pt AST-Dry cases show minor changes in spatial current distributions. Moreover, a preferential growth of Pt particles under serpentine flow field bends in the Pt AST-Wet case is observed for the first time. This study provides crucial insights into the role of mass transport properties in shaping fuel cell performance, and highlights the need to consider factors beyond electrochemically-active surface area (ECSA) when assessing fuel cell durability.

Surface engineering for stable electrocatalysis

In recent decades, significant progress has been achieved in rational developments of electrocatalysts through constructing novel atomistic structures and modulating catalytic surface topography, realizing substantial enhancement in electrocatalytic activities. Numerous advanced catalysts were developed for electrochemical energy conversion, exhibiting low overpotential, high intrinsic activity, and selectivity. Yet, maintaining the high catalytic performance under working conditions with high polarization and vigorous microkinetics that induce intensive degradation of surface nanostructures presents a significant challenge for commercial applications. Recently, advanced operando and computational techniques have provided comprehensive mechanistic insights into the degradation of surficial functional structures. Additionally, various innovative strategies have been devised and proven effective in sustaining electrocatalytic activity under harsh operating conditions. This review aims to discuss the most recent understanding of the degradation microkinetics of catalysts across an entire range of anodic to cathodic polarizations, encompassing processes such as oxygen evolution and reduction, hydrogen reduction, and carbon dioxide reduction. Subsequently, innovative strategies adopted to stabilize the materials' structure and activity are highlighted with an in-depth discussion of the underlying rationale. Finally, we present conclusions and perspectives regarding future research and development. By identifying the research gaps, this review aims to inspire further exploration of surface degradation mechanisms and rational design of durable electrocatalysts, ultimately contributing to the large-scale utilization of electroconversion technologies.

Membranes Matter: Preventing Ammonia Crossover during Electrochemical Ammonia Synthesis

The electrochemical nitrogen and nitrate reduction reactions (E-NRR and E-NO3RR) promise to provide decentralized and fossil-fuel-free ammonia synthesis, and as a result, E-NRR and E-NO3RR research has surged in recent years. Membrane NH3/NH4+ crossover during E-NRR and E-NO3RR decreases Faradaic efficiency and thus the overall yield. During catalyst evaluation, such unaccounted-for crossover results in measurement error. Herein, several commercially available membranes were screened and evaluated for use in ammonia-generating electrolyzers. NH3/NH4+ crossover of the commonly used cation-exchange membrane (CEM) Nafion 212 was measured in an H-cell architecture and found to be significant. Interestingly, some anion exchange membranes (AEMs) show negligible NH4+ crossover, addressing the problem of measurement error due to NH4+ crossover. Further investigation of select membranes in a zero-gap gas diffusion electrode (GDE)-cell determines that most membranes show significant NH3 crossover when the cell is in an open circuit. However, uptake and crossover of NH3 are mitigated when -1.6 V is applied across the GDE-cell. The results of this study present AEMs as a useful alternative to CEMs for H-cell E-NRR and E-NO3RR electrolyzer studies and present critical insight into membrane crossover in zero-gap GDE-cell E-NRR and E-NO3RR electrolyzers.

Proton Transport Functionality-Enabled Carbon Support for Improved Fuel Cell Performance and Durability

A novel Monarch carbon material with proton conduction capability due to the presence of sulfone/sulfoxide/sulfonic groups on the surface was evaluated as a potential cathode catalyst support to enable an electrode design with low ionomer content in proton exchange membrane (PEM) fuel cells. X-ray photoelectron spectroscopy of the carbon support confirmed the sulfonic acid functionality, while dynamic vapor sorption measurements proved higher water uptake. Electrochemical impedance spectroscopy of the PtCo/Monarch electrodes showed higher proton conductivity than state-of-the-art PtCo/C with decreasing ionomer to carbon (I/C) content due to the presence of sulfonic acid functional groups on the carbon support surface. Fuel cell performance and durability measurements showed better high-current density performance for PtCo/Monarch with a 75% lower ionomer content in the electrode compared to that of PtCo/C. Our studies indicate that Monarch carbon could be a viable alternative support for PEM fuel cell catalyst applications.

Promoting ordering degree of intermetallic fuel cell catalysts by low-melting-point metal doping

Carbon supported intermetallic compound nanoparticles with high activity and stability are promising cathodic catalysts for oxygen reduction reaction in proton-exchange-membrane fuel cells. However, the synthesis of intermetallic catalysts suffers from large diffusion barrier for atom ordering, resulting in low ordering degree and limited performance. We demonstrate a low-melting-point metal doping strategy for the synthesis of highly ordered L10-type M-doped PtCo (M = Ga, Pb, Sb, Cu) intermetallic catalysts. We find that the ordering degree of the M-doped PtCo catalysts increases with the decrease of melting point of M. Theoretic studies reveal that the low-melting-point metal doping can decrease the energy barrier for atom diffusion. The prepared highly ordered Ga-doped PtCo catalyst exhibits a large mass activity of 1.07 A mgPt-1 at 0.9 V in H2-O2 fuel cells and a rated power density of 1.05 W cm-2 in H2-air fuel cells, with a Pt loading of 0.075 mgPt cm-2.

Regulating Catalytic Properties and Thermal Stability of Pt and PtCo Intermetallic Fuel-Cell Catalysts via Strong Coupling Effects between Single-Metal Site-Rich Carbon and Pt

Developing low platinum-group-metal (PGM) catalysts for the oxygen reduction reaction (ORR) in proton-exchange membrane fuel cells (PEMFCs) for heavy-duty vehicles (HDVs) remains a great challenge due to the highly demanded power density and long-term durability. This work explores the possible synergistic effect between single Mn site-rich carbon (MnSA-NC) and Pt nanoparticles, aiming to improve intrinsic activity and stability of PGM catalysts. Density functional theory (DFT) calculations predicted a strong coupling effect between Pt and MnN4 sites in the carbon support, strengthening their interactions to immobilize Pt nanoparticles during the ORR. The adjacent MnN4 sites weaken oxygen adsorption at Pt to enhance intrinsic activity. Well-dispersed Pt (2.1 nm) and ordered L12-Pt3Co nanoparticles (3.3 nm) were retained on the MnSA-NC support after indispensable high-temperature annealing up to 800 °C, suggesting enhanced thermal stability. Both PGM catalysts were thoroughly studied in membrane electrode assemblies (MEAs), showing compelling performance and durability. The Pt@MnSA-NC catalyst achieved a mass activity (MA) of 0.63 A mgPt-1 at 0.9 ViR-free and maintained 78% of its initial performance after a 30,000-cycle accelerated stress test (AST). The L12-Pt3Co@MnSA-NC catalyst accomplished a much higher MA of 0.91 A mgPt-1 and a current density of 1.63 A cm-2 at 0.7 V under traditional light-duty vehicle (LDV) H2-air conditions (150 kPaabs and 0.10 mgPt cm-2). Furthermore, the same catalyst in an HDV MEA (250 kPaabs and 0.20 mgPt cm-2) delivered 1.75 A cm-2 at 0.7 V, only losing 18% performance after 90,000 cycles of the AST, demonstrating great potential to meet the DOE targets.

Quantification of PEFC Catalyst Layer Saturation via In Silico, Ex Situ, and In Situ Small-Angle X-ray Scattering

The complex nature of liquid water saturation of polymer electrolyte fuel cell (PEFC) catalyst layers (CLs) greatly affects the device performance. To investigate this problem, we present a method to quantify the presence of liquid water in a PEFC CL using small-angle X-ray scattering (SAXS). This method leverages the differences in electron densities between the solid catalyst matrix and the liquid water filled pores of the CL under both dry and wet conditions. This approach is validated using ex situ wetting experiments, which aid the study of the transient saturation of a CL in a flow cell configuration in situ. The azimuthally integrated scattering data are fitted using 3D morphology models of the CL under dry conditions. Different wetting scenarios are realized in silico, and the corresponding SAXS data are numerically simulated by a direct 3D Fourier transformation. The simulated SAXS profiles of the different wetting scenarios are used to interpret the measured SAXS data which allows the derivation of the most probable wetting mechanism within a flow cell electrode.

Alternative and facile production pathway towards obtaining high surface area PtCo/C intermetallic catalysts for improved PEM fuel cell performance

The design of catalysts with stable and finely dispersed platinum or platinum alloy nanoparticles on the carbon support is key in controlling the performance of proton exchange membrane (PEM) fuel cells. In the present work, an intermetallic PtCo/C catalyst is synthesized via double-passivation galvanic displacement. TEM and XRD confirm a significantly narrowed particle size distribution for the catalyst particles compared to commercial benchmark catalysts (Umicore PtCo/C). Only about 10% of the mass fraction of PtCo particles show a diameter larger than 8 nm, whereas this is up to or even more than 35% for the reference systems. This directly results in a considerable increase in electrochemically active surface area (96 m² g^-1 vs. >70 m² g^-1), which confirms the more efficient usage of precious catalyst metal in the novel catalyst. Single-cell tests validate this finding by improved PEM fuel cell performance. Reducing the cathode catalyst loading from 0.4 mg cm^-2 to 0.25 mg cm^-2 resulted in a power density drop at an application-relevant 0.7 V of only 4% for the novel catalyst, compared to the 10% and 20% for the commercial benchmarks reference catalysts.

Preparation and Performance Study of the Anodic Catalyst Layer via Doctor Blade Coating for PEM Water Electrolysis

The membrane electrode assembly (MEA) is the core component of proton exchange membrane (PEM) water electrolysis cell, which provides a place for water decomposition to generate hydrogen and oxygen. The microstructure, thickness, IrO₂ loading as well as the uniformity and quality of the anodic catalyst layer (ACL) have great influence on the performance of PEM water electrolysis cell. Aiming at providing an effective and low-cost fabrication method for MEA, the purpose of this work is to optimize the catalyst ink formulation and achieve the ink properties required to form an adherent and continuous layer with doctor blade coating method. The ink formulation (e.g., isopropanol/H₂O of solvents and solids content) were adjusted, and the doctor blade thickness was optimized. The porous structure and the thickness of the doctor blade coating ACL were further confirmed with the in-plane and the cross-sectional SEM analyses. Finally, the effect of the ink formulation and the doctor blade thickness of the ACL on the cell performance were characterized in a PEM electrolyzer under ambient pressure at 80 °C. Overall, the optimized doctor blade coating ACL showed comparable performance to that prepared with the spraying method. It is proved that the doctor blade coating is capable of high-uniformity coating.

Ethanol Electrooxidation at 1-2 nm AuPd Nanoparticles

We report a systematic study of the electrocatalytic properties and stability of a series of 1-2 nm Au, Pd, and AuPd alloy nanoparticles (NPs) for the ethanol oxidation reaction (EOR). Following EOR electrocatalysis, NP sizes and compositions were characterized using aberration-corrected scanning transmission electron microscopy (ac-STEM) and energy dispersive spectroscopy (EDS). Two main findings emerge from this study. First, alloyed AuPd NPs exhibit enhanced electrocatalytic EOR activity compared to either monometallic Au or Pd NPs. Specifically, NPs having a 3:1 ratio of Au:Pd exhibit an ~8-fold increase in peak current density compared to Pd NPs, with an onset potential shifted ~200 mV more to the negative compared to Au NPs. Second, the size and composition of AuPd alloy NPs do not (within experimental error) change following 1.0 or 2.0 h chronoamperometry experiments, while monometallic Au NPs increase in size from 2 to 5 nm under the same conditions. Notably, this report demonstrates the importance of post-catalytic ac-STEM/EDS characterization for fully evaluating NP activity and stability, especially for 1-2 nm NPs that may change in size or structure during electrocatalysis.

Oxygen Plasma-Mediated Microstructured Hydrocarbon Membrane for Improving Interface Adhesion and Mass Transport in Polymer Electrolyte Fuel Cells

Developing a method for fabricating high-efficient and low-cost fuel cells is imperative for commercializing polymer electrolyte membrane (PEM) fuel cells (FCs). This study introduces a mechanical and chemical modification technique using the oxygen plasma irradiation process for hydrocarbon-based (HC) PEM. The oxygen functional groups were introduced on the HC-PEM surface through the plasma process in the controlled area, and microsized structures were formed. The modified membrane was incorporated with plasma-treated electrodes, improving the adhesive force between the HC-PEM and the electrode. The decal transfer was enabled at low temperatures and pressures, and the interfacial resistance in the membrane-electrode assembly (MEA) was reduced. Furthermore, the micropillar structured electrode configuration significantly reduced the oxygen transport resistance in the MEA. Various diagnostic techniques were conducted to find out the effects of the membrane surface modification, interface adhesion, and mass transport, such as physical characterizations, mechanical stress tests, and diverse electrochemical measurements.

Small molecule-assisted synthesis of carbon supported platinum intermetallic fuel cell catalysts

Supported ordered intermetallic compounds exhibit superior catalytic performance over their disordered alloy counterparts in diverse reactions. But the synthesis of intermetallic compounds catalysts often requires high-temperature annealing that leads to the sintering of metals into larger crystallites. Herein, we report a small molecule-assisted impregnation approach to realize the general synthesis of a family of intermetallic catalysts, consisting of 18 binary platinum intermetallic compounds supported on carbon blacks. The molecular additives containing heteroatoms (that is, O, N, or S) can be coordinated with platinum in impregnation and thermally converted into heteroatom-doped graphene layers in high-temperature annealing, which significantly suppress alloy sintering and insure the formation of small-sized intermetallic catalysts. The prepared optimal PtCo intermetallics as cathodic oxygen-reduction catalysts exhibit a high mass activity of 1.08 A mg_Pt^-1 at 0.9 V in H₂-O₂ fuel cells and a rated power density of 1.17 W cm^-2 in H₂-air fuel cells.

Revealing the role of ionic liquids in promoting fuel cell catalysts reactivity and durability

Ionic liquids (ILs) have shown to be promising additives to the catalyst layer to enhance oxygen reduction reaction in polymer electrolyte fuel cells. However, fundamental understanding of their role in complex catalyst layers in practically relevant membrane electrode assembly environment is needed for rational design of highly durable and active platinum-based catalysts. Here we explore three imidazolium-derived ionic liquids, selected for their high proton conductivity and oxygen solubility, and incorporate them into high surface area carbon black support. Further, we establish a correlation between the physical properties and electrochemical performance of the ionic liquid-modified catalysts by providing direct evidence of ionic liquids role in altering hydrophilic/hydrophobic interactions within the catalyst layer interface. The resulting catalyst with optimized interface design achieved a high mass activity of 347 A g-1Pt at 0.9 V under H2/O2, power density of 0.909 W cm-2 under H2/air and 1.5 bar, and had only 0.11 V potential decrease at 0.8 A cm-2 after 30 k accelerated stress test cycles. This performance stems from substantial enhancement in Pt utilization, which is buried inside the mesopores and is now accessible due to ILs addition.

Tracking Nanoparticle Degradation across Fuel Cell Electrodes by Automated Analytical Electron Microscopy

Nanoparticles are an important class of materials that exhibit special properties arising from their high surface area-to-volume ratio. Scanning transmission electron microscopy (STEM) has played an important role in nanoparticle characterization, owing to its high spatial resolution, which allows direct visualization of composition and morphology with atomic precision. This typically comes at the cost of sample size, potentially limiting the accuracy and relevance of STEM results, as well as the ability to meaningfully track changes in properties that vary spatially. In this work, automated STEM data acquisition and analysis techniques are employed that enable physical and compositional properties of nanoparticles to be obtained at high resolution over length scales on the order of microns. This is demonstrated by studying the localized effects of potential cycling on electrocatalyst degradation across proton exchange membrane fuel cell cathodes. In contrast to conventional, manual STEM measurements, which produce particle size distributions representing hundreds of particles, these high-throughput automated methods capture tens of thousands of particles and enable nanoparticle size, number density, and composition to be measured as a function of position within the cathode. Comparing the properties of pristine and degraded fuel cells provides statistically robust evidence for the inhomogeneous nature of catalyst degradation across electrodes. These results demonstrate how high-throughput automated STEM techniques can be utilized to investigate local phenomena occurring in nanoparticle systems employed in practical devices.

Effect of Commercial Gas Diffusion Layers on Catalyst Durability of Polymer Electrolyte Fuel Cells in Varied Cathode Gas Environment

Gas diffusion layers (GDLs) play a crucial role in heat transfer and water management of cathode catalyst layers in polymer electrolyte fuel cells (PEFCs). Thermal and water gradients can accelerate electrocatalyst degradation and therefore the selection of GDLs can have a major influence on PEFC durability. Currently, the role of GDLs in electrocatalyst degradation is poorly studied. In this study, electrocatalyst accelerated stress test studies are performed on membrane electrode assemblies (MEAs) prepared using three most commonly used GDLs. The effect of GDLs on electrocatalyst degradation is evaluated in both nitrogen (non-reactive) and air (reactive) gas environments at 100% relative humidity. In situ electrochemical characterization and extensive physical characterization is performed to understand the subtle differences in electrocatalyst degradation and correlated to the use of different GDLs. Overall, no difference is observed in the electrocatalyst degradation due to GDLs based on polarization curves at the end of life. But interestingly, MEA with a cracked microporous layer (MPL) in the GDL exhibited a higher electrocatalyst loading loss, which resulted in a lower and more heterogeneous increase in the average electrocatalyst nanoparticle size.

Atomically dispersed Pt and Fe sites and Pt–Fe nanoparticles for durable proton exchange membrane fuel cells

Proton exchange membrane fuel cells convert hydrogen and oxygen into electricity without emissions. The high cost and low durability of Pt-based electrocatalysts for the oxygen reduction reaction hinder their wide application, and the development of non-precious metal electrocatalysts is limited by their low performance. Here we design a hybrid electrocatalyst that consists of atomically dispersed Pt and Fe single atoms and Pt–Fe alloy nanoparticles. Its Pt mass activity is 3.7 times higher than that of commercial Pt/C in a fuel cell. More importantly, the fuel cell with a low Pt loading in the cathode (0.015 mgPt cm−2) shows an excellent durability, with a 97% activity retention after 100,000 cycles and no noticeable current drop at 0.6 V for over 200 hours. These results highlight the importance of the synergistic effects among active sites in hybrid electrocatalysts and provide an alternative way to design more active and durable low-Pt electrocatalysts for electrochemical devices.

Transport and Electrochemical Interface Properties of Ionomers in Low-Pt Loading Catalyst Layers: Effect of Ionomer Equivalent Weight and Relative Humidity

Catalyst layer (CL) ionomers control several transport and interfacial phenomena including long-range transport of protons, local transport of oxygen to Pt catalyst, effective utilization of Pt catalyst, electrochemical reaction kinetics and double-layer capacitance. In this work, the variation of these properties, as a function of humidity, for CLs made with two ionomers differing in side-chain length and equivalent weight, Nafion-1100 and Aquivion-825, was investigated. This is the first study to examine humidity-dependent oxygen reduction reaction (ORR) kinetics in-situ for CLs with different ionomers. A significant finding is the observation of higher ORR kinetic activity (A/cm²_Pt) for the Aquivion-825 CL than for the Nafion-1100 CL. This is attributed to differences in the interfacial protonic concentrations at Pt/ionomer interface in the two CLs. The differences in Pt/ionomer interface is also noted in a higher local oxygen transport resistance for Aquivion-825 CLs compared to Nafion-1100 CLs, consistent with stronger interaction between ionomer and Pt for ionomer with more acid groups. Similar dependency on Pt utilization (ratio of electrochemically active area at any relative humidity (RH) to that at 100% RH) as a function of RH is observed for the two CLs. As expected, strong influence of humidity on proton conduction is observed. Amongst the two, the CL with high equivalent weight ionomer (Nafion-1100) exhibits higher conduction.

Modifying the Electrocatalyst-Ionomer Interface via Sulfonated Poly(ionic liquid) Block Copolymers to Enable High-Performance Polymer Electrolyte Fuel Cells

Polymer electrolyte membrane fuel cell (PEMFC) electrodes with a 0.07 mgPt cm-2 Pt/Vulcan electrocatalyst loading, containing only a sulfonated poly(ionic liquid) block copolymer (SPILBCP) ionomer, were fabricated and achieved a ca. 2× enhancement of kinetic performance through the suppression of Pt surface oxidation. However, SPILBCP electrodes lost over 70% of their electrochemical active area at 30% RH because of poor ionomer network connectivity. To combat these effects, electrodes made with a mix of Nafion/SPILBCP ionomers were developed. Mixed Nafion/SPILBCP electrodes resulted in a substantial improvement in MEA performance across the kinetic and mass transport-limited regions. Notably, this is the first time that specific activity values determined from an MEA were observed to be on par with prior half-cell results for Nafion-free Pt/Vulcan systems. These findings present a prospective strategy to improve the overall performance of MEAs fabricated with surface accessible electrocatalysts, providing a pathway to tailor the local electrocatalyst/ionomer interface.

PGM-Free Fe/N/C and Ultralow Loading Pt/C Hybrid Cathode Catalysts with Enhanced Stability and Activity in PEM Fuel Cells

In this work, the stability behaviors of the state-of-the-art Fe/N/C and Pt/C catalysts (as well as the activation time of the latter) were first systematically investigated, under different cathode catalyst loadings, in the membrane electrode assemblies (MEA) in PEM fuel cells. Based on that, two types of cathode electrodes with the combination of Fe/N/C and Pt/C catalysts were developed (type I: layered hybrid catalysts with Pt/C next to the membrane and type II: uniformly mixed catalysts). In this way, the shortcomings of the Fe/N/C catalyst (the fast decay) and the Pt/C catalyst (the long activation time) can be compensated at the same time. The hybrid catalysts also showed a very short activation time (a few hours vs over 10 h for Pt/C with the same Pt loading). Comparing the two types of hybrid catalysts, type I shows a much higher current density. The loadings of the Fe/N/C and Pt/C catalysts in the hybrid electrode were systematically studied, with optimal values of 1.0 mg cm^-2 for Fe/N/C and 0.035 mg_Pt cm^-2 for Pt/C. The Pt loading of this hybrid catalyst (type I) at the cathode only takes ca. 30% of the U.S. Department of Energy (DOE) target of Pt usage (0.100 mg_Pt cm^-2), while its mass activity of Pt (in H₂/O₂ PEMFC) is 0.22 A mg_Pt^-1 at 0.9_iR-free V, reaching half of the DOE activity target (0.44 A mg_Pt^-1), which is among the best performances reported so far. Via both half-cell and single-cell electrochemical evaluations together with other characterizations, the origin of the improved activity and stability is believed to be the synergistic effect between Pt/C and Fe/N/C catalysts to ORR. This work provides an effective strategy for engineering highly performing MEA for the industrialization of PEM fuel cells.

Dictating Pt-Based Electrocatalyst Performance in Polymer Electrolyte Fuel Cells, from Formulation to Application

In situ electrochemical diagnostics designed to probe ionomer interactions with platinum and carbon were applied to relate ionomer coverage and conformation, gleaned from anion adsorption data, with O₂ transport resistance for low-loaded (0.05 mg_Pt cm^-2) platinum-supported Vulcan carbon (Pt/Vu)-based electrodes in a polymer electrolyte fuel cell. Coupling the in situ diagnostic data with ex situ characterization of catalyst inks and electrode structures, the effect of ink composition is explained by both ink-level interactions that dictate the electrode microstructure during fabrication and the resulting local ionomer distribution near catalyst sites. Electrochemical techniques (CO displacement and ac impedance) show that catalyst inks with higher water content increase ionomer (sulfonate) interactions with Pt sites without significantly affecting ionomer coverage on the carbon support. Surprisingly, the higher anion adsorption is shown to have a minor impact on specific activity, while exhibiting a complex relationship with oxygen transport. Ex situ characterization of ionomer suspensions and catalyst/ionomer inks indicates that the lower ionomer coverage can be correlated with the formation of large ionomer aggregates and weaker ionomer/catalyst interactions in low-water content inks. These larger ionomer aggregates resulted in increased local oxygen transport resistance, namely, through the ionomer film, and reduced performance at high current density. In the water-rich inks, the ionomer aggregate size decreases, while stronger ionomer/Pt interactions are observed. The reduced ionomer aggregation improves transport resistance through the ionomer film, while the increased adsorption leads to the emergence of resistance at the ionomer/Pt interface. Overall, the high current density performance is shown to be a nonmonotonic function of ink water content, scaling with the local gas (H₂, O₂) transport resistance resulting from pore, thin film, and interfacial phenomena.