Ionic Conductivity over Metal/Water Interfaces in Ionomer‐Free Fuel Cell Electrodes

Coaxial Nanowire Electrodes Enable Exceptional Fuel Cell Durability

Polymer-electrolyte-membrane fuel cells (PEMFCs) hold great promise for applications in clean energy conversion, but cost and durability continue to limit commercialization. This work presents a new class of catalyst/electrode architecture that does not rely on Pt particles or carbon supports, eliminating the primary degradation mechanisms in conventional electrodes, and thereby enabling transformative durability improvements. The coaxial nanowire electrode (CANE) architecture consists of an array of vertically aligned nanowires, each comprising an ionomer core encapsulated by a nanoscale Pt film. This unique design eliminates the triple-phase boundary and replaces it with two double-phase boundaries, increasing Pt utilization. It also eliminates the need for carbon support and ionomer binder, enabling improved durability and faster mass transport. Fuel cell membrane electrode assemblies based on CANEs demonstrate extraordinary durability in accelerated stress tests (ASTs), with only 2% and 5% loss in performance after 5000 support AST cycles and 30000 catalysts AST cycles, respectively. The high power density and extremely high durability provided by CANEs can enable a paradigm shift from random electrodes based on unstable platinum nanoparticles dispersed on carbon to ordered electrodes based on durable Pt nanofilms, facilitating rapid deployment of fuel cells in transportation and other clean energy applications.

Effects of Cathode GDL Gradient Porosity Distribution along the Flow Channel Direction on Gas-Liquid Transport and Performance of PEMFC

The gas diffusion layer (GDL) is an important component of proton exchange membrane fuel cells (PEMFCs), and its porosity distribution has considerable effects on the transport properties and durability of PEMFCs. A 3-D two-phase flow computation fluid dynamics model was developed in this study, to numerically investigate the effects of three different porosity distributions in a cathode GDL: gradient-increasing (Case 1), gradient-decreasing (Case 3), and uniform constant (Case 2), on the gas-liquid transport and performance of PEMFCs; the novelty lies in the porosity gradient being along the channel direction, and the physical properties of the GDL related to porosity were modified accordingly. The results showed that at a high current density (2400 mA·cm^-2), the GDL of Case 1 had a gas velocity of up to 0.5 cm·s^-1 along the channel direction. The liquid water in the membrane electrode assembly could be easily removed because of the larger gas velocity and capillary pressure, resulting in a higher oxygen concentration in the GDL and the catalyst layer. Therefore, the cell performance increased. The voltage in Case 1 increased by 8% and 71% compared to Cases 2 and 3, respectively. In addition, this could ameliorate the distribution uniformity of the dissolved water and the current density in the membrane along the channel direction, which was beneficial for the durability of the PEMFC. The distribution of the GDL porosity at lower current densities had a less significant effect on the cell performance. The findings of this study may provide significant guidance for the design and optimization of the GDL in PEMFCs.

Challenges in applying highly active Pt-based nanostructured catalysts for oxygen reduction reactions to fuel cell vehicles

The past 30 years have seen progress in the development of Pt-based nanocatalysts for the oxygen reduction reaction, and some are now in production on a commercial basis and used for polymer electrolyte fuel cells (PEFCs) for automotives and other applications. Further improvements in catalytic activity are required for wider uptake of PEFCs, however. In laboratories, researchers have developed various catalysts that have much higher activities than commercial ones, and these state-of-the-art catalysts have potential to improve energy conversion efficiencies and reduce the usage of platinum in PEFCs. There are several technical issues that must be solved before they can be applied in fuel cell vehicles, which require a high power density and practical durability, as well as high efficiency. In this Review, the development history of Pt-based nanocatalysts and recent analytical studies are summarized to identify the origin of these technical issues. Promising strategies for overcoming those issues are also discussed.

Synergetic Structural Transformation of Pt Electrocatalyst into Advanced 3D Architectures for Hydrogen Fuel Cells

A new direction for developing electrocatalysts for hydrogen fuel cell systems has emerged, based on the fabrication of 3D architectures. These new architectures include extended Pt surface building blocks, the strategic use of void spaces, and deliberate network connectivity along with tortuosity, as design components. Various strategies for synthesis now enable the functional and structural engineering of these electrocatalysts with appropriate electronic, ionic, and electrochemical features. The new architectures provide efficient mass transport and large electrochemically active areas. To date, although there are few examples of fully functioning hydrogen fuel cell devices, these 3D electrocatalysts have the potential to achieve optimal cell performance and durability, exceeding conventional Pt powder (i.e., Pt/C) electrocatalysts. This progress report highlights the various 3D architectures proposed for Pt electrocatalysts, advances made in the fabrication of these structures, and the remaining technical challenges. Attempts to develop design rules for 3D architectures and modeling, provide insights into their achievable and potential performance. Perspectives on future developments of new multiscale designs are also discussed along with future study directions.

Mapping Localized Peroxyl Radical Generation on a PEM Fuel Cell Catalyst Using Integrated Scanning Electrochemical Cell Microspectroscopy

Understanding molecular-level transformations resulting from electrochemical reactions is important in designing efficient and reliable energy technologies. In this work, a novel integrated scanning electrochemical cell microspectroscopy (iSECCMS) capability is developed by combining a high spatial resolution electrochemical scanning probe with in situ fluorescence spectroscopy. Using 6-carboxyfluorescein as a fluorescent probe, the iSECCMS platform is employed to measure the effect of the detrimental generation of reactive oxygen species (ROS) formed at the active sites of oxygen reduction reaction (ORR) catalysts. Carbon-supported tantalum-doped titanium oxide (TaTiOx) catalysts, a potential Pt-group-metal-free (PGM-free) cathode material explored for low temperature polymer electrolyte fuel cells (PEFCs), is used as a representative model ORR system, where generation of intermediate H2O2 instead of fully oxidized H2O is a major concern. We establish that the iSECCMS platform provides a novel and versatile capability for spatially resolved mapping of in situ ROS generation and activity during the kinetically-limited ORR and may, therefore, aid the future characterization and development of high-performance PGM-free PEFC cathodes.