Membranes and Materials for Energy Efficiency; Subtopic c Title: Development of Corrosion Resistant Carbon Support for Ultra-low PGM Catalysts

Carbon is used as a support material for both anode and cathode catalysts in state-of-the-art polymer electrolyte membrane (PEM) fuel cells. Carbon support is susceptible to corrosion under the cathode operating conditions such as presence of oxygen and water, low pH, and high potential at the cathode interface. Corrosion of state-of-the-art carbon supports is inevitable, which leads to platinum catalyst particle detachment from the support and subsequent poor performance. Alternative non-carbon supports such as metal oxides and conducting or non-conducting polymers do not meet all the 2020 DOE technical targets for both the electrocatalyst and catalyst support. Hence, modifications to the carbon supports that makes them more corrosion resistant are of great importance achieve the DOE targets. A commercially available carbon is subjected to various treatments to tailor the physical properties such as the specific surface area, pore size distribution, and hydrophilicity/hydrophobicity without sacrificing the electronic conductivity. Surface functionalization using an inexpensive bifunctional additive helps achieve uniform catalyst particle distribution and enhances catalyst/support interaction, which is critical for PEM fuel cells operating under transient conditions. Phase I of the proposed project will focus on the synthesis of a corrosion resistant carbon (CRC) support and Pt/CRC and Pt-alloy/CRC catalysts. Extensive physical characterization, rotating disc electrode (RDE) studies, and fuel cell testing in 25 cm2 membrane electrode assembly (MEA) will be performed to understand the structure-property relationship of the developed support and catalysts. The support properties will be tailored to increase the high current density fuel cell performance with H2-air feeds. Accelerated stress test (AST) protocols utilized by the U.S DRIVE Fuel Cell Tech Team will be employed to evaluate the ability of the supported electrocatalysts to meet the 2020 DOE targets. Commercial Application and Public Benefits: If successful, the proposed CRC support and Pt-alloy/CRC catalyst will increase the life of automotive fuel cells and replace the currently used carbon supports in PEM fuel cell catalysts. The outcome of Phase I results will drive the continued research and development of CRC support and Pt-alloy/CRC catalyst in Phase II followed by scale-up and commercialization when targets are met. Generating encouraging and reproducible results during Phase I and II R&D efforts will provide confidence to investors to set up a pilot scale production facility in South Carolina that will provide job opportunities.