Enhancing PEMFC Performance: Optimization of Hot-Pressed Decal Transfer Conditions for MEA Fabrication

Proton exchange membrane fuel cells (PEMFCs) hold significant promise in curbing greenhouse gas emissions within the transportation sector. While historically more expensive than conventional internal combustion engines, the cost per kW is poised to significantly drop as production volumes increase and the adoption of fuel cell electric vehicles progresses [1]. In heavy-duty vehicle applications, predictions suggest that hydrogen fuel cells will achieve a cost equivalence with diesel, potentially becoming the most cost-effective option when evaluating the total ownership expenses [2]. Membrane-electrode-assemblies (MEAs) serve as the core of fuel cells, where all reactions—proton and electron generation, distribution, and consumption occur. Their efficiency dictates both cell performance and lifespan. Various methods for fabricating MEAs have been developed, including decal transfer, catalyst-coated membrane (CCM), and catalyst-coated gas diffusion layer (CCG) techniques. Among these, the decal transfer method is widely regarded as the most appropriate for large-scale production of MEAs [3]. This study delves into an examination of diverse hot-pressed decal transfer conditions for the preparation of MEAs tailored for PEMFC application. Our investigation involves fabricating MEAs through hot-press decal transfer at temperatures spanning 115°C to 145°C and pressures ranging from 200 psi to 400 psi, each held for a 5-minute duration. Electrochemical characterizations were performed within a single-cell setup to assess MEA performance. Moreover, an accelerated stress test (AST) was carried out to scrutinize the stability of the fabricated MEAs concerning their decal transfer conditions and morphological variations. Our study extensively explored catalyst layers transferred under diverse hot-pressed decal transfer conditions, focusing on their fuel cell performance and transport properties. To comprehensively understand the influence of morphological alterations on electrochemical characteristics, additional morphological characterizations, including white light interferometer (WLI) imaging, field emission scanning electron microscopy (FESEM), Brunauer-Emmett-Teller (BET) surface area analysis, and nano-computed tomography (Nano-CT) were employed for MEA evaluation. Our findings indicate that the MEA produced at 145°C and 200 psi exhibited superior performance in both pre- and post-AST testing. Comprehensive experimental results and insights will be elaborated upon during the conference presentation. References [1] Kampker A, Heimes H, Kehrer M, Hagedorn S, Reims P, Kaul O. Fuel cell system production cost modeling and analysis. Energy Rep 9 , 248–255 (2023). [2] Dodds PE, Ekins P. A portfolio of powertrains for the UK: An energy systems analysis. Int J Hydrogen Energy 39 , 13941–13953 (2014). [3] Mauger SA, Wang M, Cetinbas FC, Dzara MJ, Park J, Myers DJ, et al. Development of high-performance roll-to-roll-coated gas-diffusion-electrode-based fuel cells. J Power Sources 506 , 230039 (2021).