Polymer electrolyte membrane fuel cells (PEMFCs) have emerged as leading power source candidates for electric vehicles due to their ultimate cleanness, high efficiency and rapid refueling capabilities. Their ability to facilitate fast refueling with minimal dead mass penalty, unlike Li-ion batteries, positions fuel cells as ideal power plants for heavy-duty vehicles (HDVs) such as electric long-haul trucks, coaches, ships and airplanes, each with unique drive cycles and operational requirements. These applications demand catalyst, ionomer and membrane with enhanced durability compared to light duty vehicles (LDVs). In addition, PEMFCs operating with pure oxygen exhibit superior performance and efficiency but may face heightened challenges regarding durability of membrane electrode assembly (MEA). Presently, catalyst and MEA stability are evaluated for durability using the protocol of accelerated stress test (AST) under hydrogen/nitrogen (anode/cathode) atmosphere. Comparing with nitrogen atmosphere, the air will exert more significant degradation on both catalysts and ionomer/membranes. However, the impact of hydrogen/air condition, particularly under HDV operating conditions, on catalyst, ionomer, membrane degradation and their differences from the hydrogen/nitrogen condition remains unclearly understood. In this work, two MEAs fabricated by our highly active catalysts, specifically 30wt% Pt/KB, as the cathode and a commercial Pt/C catalyst as the anode. These MEAs underwent testing under HDV conditions (250 kPa back pressure) at various relative humilities, following the standard protocol of accelerated stress test (AST) in hydrogen/nitrogen and hydrogen/air (M2FCT) for 180k cycles. The results indicate substantial performance degradation in both MEAs during AST cycling. MEAs subjected to AST in hydrogen/nitrogen maintained the current density of 1.4 A/cm2, 1.2 A/cm2, 1.0 A/cm2 and 0.9 A/cm2 at the cell voltage of 0.7 V after the AST of 30k, 60k, 90k and 120k cycles, respectively. Moreover, the hydrogen/nitrogen MEA performance significantly declined to 0.5 A/cm2 and 0.3 A/cm2 at the same voltage after 150k and 180k cycles, respectively. In comparison, the MEA tested with AST in hydrogen/air exhibit similar beginning-of-life performance but experienced faster performance loss, especially within the mass transfer region, accompanied with the significant increase in crossover current, which indicates the degradation of membrane. In summary, this study elucidates the distinct degradation and mechanisms observed in highly efficient and durable PGM-catalyst MEAs running AST in nitrogen and air under HDV conditions.
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