Degradation Protocols Highlighting the Influence of Graphitized Carbon Support on the Catalyst Layer and Proton Exchange Membrane Durability

Proton exchange membrane fuel cells (PEMFC) are promising zero-emission energy conversion systems. However, their widespread adoption is limited by high capital expenditures due to the use of platinum group metals in the catalyst layer. Because prolonging the catalyst’s lifetime can help offset costs, there is significant interest in understanding the degradation behavior of PEMFC catalyst layers. This study conducted accelerated stress tests (AST) and real-world maritime drive cycles using two carbon supports to evaluate their impact on fuel cell performance and durability. Extensive in situ characterizations were performed on single-cell PEMFC, where the cathode catalyst layer used either amorphous carbon or partially graphitized acetylene black as the catalyst support. The results showed that partially graphitized carbon supports minimized electrochemical surface area loss, improving catalyst layer durability. Membrane-specific AST further revealed that partially graphitized carbon supports mitigated membrane degradation as well. Finally, the performance and durability of the two carbon supports were evaluated by subjecting the PEMFC to a 500 h maritime drive cycle, underlining the effect of carbon corrosion on both catalyst layer and membrane durability. The findings emphasize the critical role of carbon support selection in optimizing PEMFC durability and highlight the intricate interplay of membrane electrode assembly components.