Heavy-duty PEM fuel cells are expected to last 25,000-30,000 hours in the field. Therefore, materials, components, and interfaces used in these systems must be highly resistant to severe mechanical and chemical stress. Novel, highly active stable Pt and ordered PtCo intermetallic nanoparticles with well-controlled particle size and composition have been synthesized on a highly efficient PGM-free single metal active site rich carbon, to maximize their synergistic effects for enhanced performance and durability. Integrating these catalysts integrated with high O2 permeability ionomer (HOPI) in membrane electrode assemblies (MEAs) improved their fuel cell performance and durability, allowing the MEAs to achieve >1.2 A/cm2 at 0.7 V after 150k square wave accelerated stress test (AST) cycles, with a performance loss < 40 mV after 150K AST cycles.In a PEM fuel cell, the catalyst ink formulation and mixing processes control catalyst layer coating quality, electrode morphology, and the resulting fuel cell performance and durability. Catalyst ink properties are a result of complex solvent-catalyst-ionomer interactions that depend on the mixing method employed. Here, we compare the performance and durability of electrodes made from ball milled inks for Mayer rod coating before and after the catalyst scale up. Ink rheology and catalyst particle size are used to correlate ink properties to electrode morphology and structure and ensure consistency from batch to batch, and from small lab scale to subsequent scale-up. We evaluate and discuss the challenges that arise when coating the more viscous inks on decals, where the HOPI creates many bubbles in the ink. We also present the challenges of hot-pressing inks that contain HOPI, and how employing a Nafion overspray made with different solvents (isopropanol vs. ethanol) can improve hot-pressing. We investigate the how ionomer to carbon ratio affects hot pressing with HOPI and crack formation in the electrode via scanning electron microscopy (SEM).This work provides a comprehensive understanding of interactions between Pt, PtCo, carbon, ionomer, membrane, and GDLs and their impact on electrode structure, fuel cell performance and durability, as well as considerations for scale up to a R2R fabrication process. The attained information will be used to improve fuel cell electrode design, fabrication and scale-up.Acknowledgement: The project is financially supported by the Department of Energy’s Fuel Cell Technology Office under the Grant DE-FOA-0002360 (Phase I) and DE-SC0021671 (Phase II). Figure 1
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