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Membrane drying, fuel cell flooding, and anode catalyst poisoning by carbon monoxide are investigated on Hydrogenics production-type proton exchange membrane fuel cell ͑PEMFC͒ stacks similar to the stacks used in Hydrogenics HyPM 10-kW fuel cell power modules. Changes in fuel cell voltage and impedance with time are presented for each type of fault, the fuel cell stacks being controlled in galvanostatic mode. This study shows that these PEMFC stack faults can be differentiated by their impedance responses while fuel cell voltage monitoring alone is insufficient to distinguish between failure types. Membrane drying leads to an increase in the fuel cell impedance magnitude and phase angle at all frequencies studied. Fuel cell flooding leads to an increase in the impedance magnitude at low frequencies ͑ f Ͻ 10 Hz͒ and to a decrease in the impedance phase angle at frequencies less than 100 Hz. Anode catalyst poisoning by CO is characterized by an increase in the fuel cell impedance magnitude at frequencies less than a few hundred Hz. For this fault, the impedance phase angle decreases within a large frequency range and is characterized by a minimum value appearing at 20-25 Hz at moderate current density.

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High efficiencies, wide operation range and rapid response time have motivated the recent interest in proton exchange membrane (PEM) electrolysis for hydrogen generation with surplus electricity. However, degradation at high current densities and the associated mechanism has not been thoroughly explored so far. In this work, membrane electrode assemblies (MEA) from different suppliers are aged in a commercial PEM electrolyzer (2.5 N m 3 H 2 h -1 ), operating up to 4 A cm -2 for more than 750 h. In all cases, the cell voltage (E cell ) decreases during the testing period. Interestingly, the cells with Ir-black anodes exhibit the highest performance with the lowest precious metal loading (1 mg cm -2 ). Electrochemical impedance spectroscopy (EIS) shows a progressive decrease in the specific exchange current, while the ohmic resistance decreases when doubling the nominal current density. This effect translates into an enhancement of cell efficiency at high current densities. However, Ir concurrently leaches out and diffuses into the membrane. No decrease in membrane thickness is observed at the end of the tests. High current densities do not lead to lowering the performance of the PEM electrolyzer over time, although MEA components degrade, in particular the anode.

Cost reduction and high efficiency are the mayor challenges for sustainable H2 production via proton exchange membrane (PEM) electrolysis. Titanium-based components such as bipolar plates (BPP) have the largest contribution to the capital cost. This work proposes the use of stainless steel BPPs coated with Nb and Ti by magnetron sputtering physical vapor deposition (PVD) and vacuum plasma spraying (VPS), respectively. The physical properties of the coatings are thoroughly characterized by scanning electron, atomic force microscopies (SEM, AFM); and X-ray diffraction, photoelectron spectroscopies (XRD, XPS). The Ti coating (50 μm) protects the stainless steel substrate against corrosion, while a 50-fold thinner layer of Nb decreases the contact resistance by almost one order of magnitude. The Nb/Ti-coated stainless steel bipolar BPPs endure the harsh environment of the anode for more than 1000 h of operation under nominal conditions, showing a potential use in PEM electrolyzers for large-scale H2 production from renewables.