On the impact of water activity on reversal tolerant fuel cell anode performance and durability

Durability of polymer electrolyte fuel cells in automotive applications can be severely affected by hydrogen starvation arising due to transients during the drive-cycle. It causes individual cell voltage reversal, yielding water electrolysis and carbon corrosion reactions at the anode, ultimately leading to catastrophic cell failure. A popular material-based mitigation strategy is to employ a reversal tolerant anode (RTA) that includes oxygen evolution reaction (OER) catalyst (e.g., IrO2) to promote water electrolysis over carbon corrosion. Here we report that RTA performance surprisingly drops under not only water-deficient but also water-excess conditions. This presents a significant technical challenge since the most common triggers for cell reversal involve excess liquid water. Our findings from detailed electro-chemical diagnostics and nano-scale X-ray computed tomography provide insight into how automotive fuel cells can overcome critical vulnerabilities using material-based solutions. Our work also highlights the need for improved materials, electrode designs, and operation strategies for robust RTAs. (C) 2016 Elsevier B.V. All rights reserved.