Nitrogen-enriched porous carbons have been discussed as supports for Pt nanoparticle catalysts deployed at cathode layers of polymer electrolyte membrane fuel cells (PEMFC). Here, we present an analysis of the chemical process of carbon surface modification using ammonolysis of preoxidized carbon blacks, and correlate their chemical structure with their catalytic activity and stability using in situ analytical techniques. Upon ammonolysis, the support materials were characterized with respect to their elemental composition, the physical surface area, and the surface zeta potential. The nature of the introduced N-functionalities was assessed by X-ray photoelectron spectroscopy. At lower ammonolysis temperatures, pyrrolic-N were invariably the most abundant surface species while at elevated treatment temperatures pyridinic-N prevailed. The corrosion stability under electrochemical conditions was assessed by in situ high-temperature differential electrochemical mass spectroscopy in a single gas diffusion layer electrode; this test revealed exceptional improvements in corrosion resistance for a specific type of nitrogen modification. Finally, Pt nanoparticles were deposited on the modified supports. In situ X-ray scattering techniques (X-ray diffraction and small-angle X-ray scattering) revealed the time evolution of the active Pt phase during accelerated electrochemical stress tests in electrode potential ranges where the catalytic oxygen reduction reaction proceeds. Data suggest that abundance of pyrrolic nitrogen moieties lower carbon corrosion and lead to superior catalyst stability compared to state-of-the-art Pt catalysts. Our study suggests with specific materials science strategies how chemically tailored carbon supports improve the performance of electrode layers in PEMFC devices.

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Differential electrochemical mass spectrometry as well as online mass spectrometry in combination with singe cell testing has been used to study carbon corrosion of typical carbon materials discussed as support for electro-catalyst in fuel cells, e.g. carbon blacks or carbon nanotubes. Beside standard tests used to study the stability under automotive LT-PEMFC conditions, additional tests were performed to try to test the stability under the operating conditions of high temperature polymer electrolyte membrane fuel cells (HT-PEMFC). It was shown that under LT-PEMFC conditions a strong catalytic effect of platinum on the carbon corrosion rate is observable. High temperatures in HT-PEMFC do accelerate the corrosion rate. It was further found that corrosion does not only occur at high potentials but also to a minor amount at lower potentials. This low potential corrosion is in particular observed after a prior potential excursion of the electrode indicating that such excursions do not only lead to the direct corrosion of the support but also to the formation of unstable surface groups, which can be removed subsequently. Throughout all tests, CNT exhibited a higher stability than the tested carbon blacks. In single cell testing, the contribution of other carbon materials in particular the MPL was evaluated. It was found that it is present but small compared to the catalyst support itself. In order to reduce the expenditure of platinum group metals in polymer electrolyte membrane fuel cells the dispersion of the catalyst on a conductive support is the current state-of the art. Only few examples do not follow this approach. Most prominent among the exemptions is the Nano-Structured Thin Film (NSTF) type of catalyst developed by 3M.1 For most applications, carbon has become, however, a sort of standard support material. To accomplish the goal to reduce costs for the fuel cells, inexpensive carbon black materials like Vulcan XC72R from Cabot are used most often. However, as carbon in presence of water is thermodynamically unstable for potentials higher than 0.207 V 2 carbon corrosion can become an issue if the oxidation of the carbon is not strongly kinetically hindered e.g. via high degrees of graphitization. Consequently, carbon materials exhibiting such high degrees of graphitization like carbon nanotubes or graphene have attracted attention as alternative supports.The focus of the research on carbon corrosion is on LT-PEMFC for automotive application. With respect to carbon corrosion the reversed current decay mechanism proposed by Reiser et al.3 is an accepted cause for this type of degradation processes. This is confirmed e.g. in the review of PEMFC degradation processes published by Yu et al. 4 The process which is induced by the formation of a hydrogen oxygen front on the anode side upon hydrogen admission after longer standstill can cause potential excursions of the cathode side to potentials between 1.4 and 1.75 V.5 Accordingly, the common tests suites published by US Department of Energy (DoE) and the Fuel Ce...