Cell voltages at high current densities (HCD) of an operating proton-exchange membrane fuel cell (PEMFC) cathode suffer from losses due to the local-O2 and bulk-H+ transport resistances in the catalyst layer. Particularly, the microstructure of high surface area carbon (HSC) support upon which both the platinum catalyst and ionomer are dispersed play a pivotal role in controlling the reactant transport to the active site in the catalyst layer. In this study, we perform a systematic analysis of the underlying microstructure of platinum-cobalt catalyst dispersed on various HSC supports in terms of their surface area and pore-size distribution. The carbon microstructure was found to strongly influence the PtCo nanoparticle dispersion, catalyst layer ionomer distribution and transport losses governing the performance at HCD. Catalyst layer electrochemical diagnostics carried out to quantify local-O2 transport resistance and bulk-H+ transport resistance in the cathode were found to be directly correlated to the micropore (<2 nm) and macropore (>8 nm) surface areas of the carbon support, respectively. Finally, a 1D-performance model has been developed to assimilate our understanding of the catalyst layer microstructure and transport resistances at HCD.

Pyrolyzed transition metal based porphyrins present an attractive alternative to state of the art Pt-based electrocatalysts for fuel cell applications based on their comparatively low cost. Unfortunately, the large array of precursors and synthetic strategies has led to considerable ambiguity regarding the specific structure/ property relationships that give rise to their activity for oxygen reduction. Specifically, considerable debate exists in actual chemical structure of the pyrolyzed reaction centers, and their relationship to membranedamaging peroxide yield. In this manuscript a comprehensive electrochemical and spectroscopic study of pyrolyzed CoTMPP produced via a self-templating process is presented. The resulting electrocatalysts are not carbon-supported, but are highly porous self-supported pyropolymers. Rotating ring disk electrode measurements showed that the materials pyrolyzed at 700 °C exhibited the highest performance, whereas pyrolysis at 800 °C resulted in a significant increase in the peroxide yield. X-ray photoelectron spectroscopy and Co L and K edge extended X-ray absorption fine structure (EXAFS) studies confirm that the majority of the Co-N 4 active site has broken down to Co-N 2 at 800 °C. Application of ∆µ analysis (an X-ray absorption near-edge structure difference technique) to the in situ Co K edge EXAFS data allowed for direct spectroscopic observation of the geometry of O ads on the pyropolymer active sites. The specific geometrical adsorption of molecular oxygen with respect to the plane of the Co-N x moieties highly influences the oxygen reduction reaction pathway. The application of the ∆µ technique to other transition metal based macrocycle electrocatalyst systems is expected to provide similarly detailed information.

Maintaining high performance after extensive use remains a key challenge for low-Pt proton exchange membrane fuel cells for transportation applications. Strategically improving catalyst durability requires better understanding of the relationship between degradation mechanisms and catalyst structure. To investigate the effects of the carbon support morphology, we compare the electrochemical performance and durability of membrane electrode assemblies (MEAs) using Pt and PtCo x catalysts with a range of porous, solid, and intermediate carbon supports (HSC, Vulcan, and acetylene black). We find that electrochemical surface area (ECSA) retention after a catalyst-targeted durability test tends to improve with increasing support porosity. Using electron microscopy, we investigate microstructural changes in the catalysts and reveal the underlying degradation mechanisms in MEA specimens. Pt migration to the membrane and catalyst coarsening, measured microscopically, together were quantitatively consistent with the ECSA loss, indicating that these were the only two significant degradation pathways. Changes in catalyst particle size, morphology, and PtCo core-shell structure indicate that Ostwald ripening is a significant coarsening mechanism for catalysts on all carbons, while particle coalescence is only significant on the more solid carbon supports. Porous carbon supports thus appear to protect against particle coalescence, providing an effective strategy for mitigating catalyst coarsening.