Towards a CO2 free energy supply, hydrogen plays an important role as a chemical energy storage capable of storing renewable energy in large dimensions. In this context, fuel cells, such as e.g. polymer electrolyte membrane fuel cells (PEMFC) are going to evolve to a key technology for the conversion of the chemically stored energy back to usable electric energy. Therefore, after decades of fuel cell research, the phase of industrialization of fuel cells has begun recently to provide fuel cells in large quantity for a variety of applications, such as e.g. to power heavy duty vehicles, ships and even airplanes or as stationary power plants.For PEMFC mass production, the optimization of the manufacturing process of fuel cells is important to decrease the manufacturing time and costs. One of the most time and cost consuming steps during the production of fuel cells is the first time activation. During the so-called break-in, the fuel cell is operated for the first time in order to activate the membrane electrode assembly (MEA). During break-in, the proton conductivity of the membrane is established and the catalyst is activated, but also chemical residues of the production of the fuel cell components were removed. This procedure is necessary for a fuel cell stack to provide its maximum power output and maximum robustness of all single cells. Furthermore, the successful activation of the PEMFC strongly affects the overall lifetime of a fuel cell stack.To date, a typical break-in of a fuel cell stack takes in between 2 and 8 hours of time, in which a considerable amount of hydrogen and air is required. Thereby, the stack is commonly operated at a high relative humidity doing several cycles of current ramps from minimum to medium or high load interrupted by shutdowns, whereby the first current ramp is usually performed very slowly. Besides the media consumption, the rather long state-of-the-art break-in time calls for a high degree of parallelization of break-in stations at each production line to reach a reasonable output of fuel cell stacks, which is related to high investment costs. An optimization of the break-in process in respect to the necessary time and media consumption significantly reduces the production costs of a PEMFC stack. In this work, several new approaches to activate PEMFCs were introduced in order to decrease the duration and media consumption of the break-in process. Thereby, the common break-in doing several current ramps was replaced by more efficient and promising approaches, such as e.g., hydrogen starvation events or hydrogen pumping. This break-in experiments were performed in short stacks of small scale as well as automotive scale. Finally, the influence of each break-in variation on the performance and durability of the PEMFC was investigated.
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