Perflourosulfonic acid (PFSA) ionomers are used in many applications including polymer-electrolyte membrane fuel cells and electrolysers owing to their many attractive properties such as excellent ion-conductivity, chemical resistance, mechanical properties, and thermal stability. In polymer-electrolyte membrane fuel cells and electrolysers, they are used as the membrane and as a component in the catalyst layers, to provide proton conductivity and serve as a binder for the catalyst particles, which are two key components of these devices. Understanding the structure and rheological properties of the ionomer dispersions is important for solution-processed fabrication of the membranes and the catalyst layers, and will enable better control their final structure/morphology, and improve the device performance. A water-alcohol solvent mixture is a common dispersion media for ionomer dispersions as well as the catalyst inks. While significant efforts exist on the structure of ionomer dispersions in water-alcohol solvent mixtures, their rheological properties, particularly the effect of solvent composition at non-dilute concentrations remain less explored. In this talk, the effect of water-alcohol (isopropanol) composition of the dispersion media on the rheological properties of ionomer dispersions will be presented. The results of small-angle x-ray scattering characterization of the ionomer dispersions will be also discussed. As a model ionomer, a short sidechain perfluorinated ionomer (PFSA), produced by 3M, was used. In dispersions with low ionomer concentrations, the zero-shear viscosity scaling with concentration was found to be similar for all alcohol fractions in the solvent mixture, following Fuoss’s law for polyelectrolytes. Whereas at higher concentrations, beyond the semi-dilute unentangled regime, their scaling was strongly dependent on alcohol fraction, where the scaling exponent increasing with increasing the alcohol fraction. Furthermore, the dispersions showed dramatic shear-thickening and strain-stiffening behaviors at higher alcohol fractions. The rheological observations suggest water-alcohol composition significantly alters the interactions between ionomer, and consequently their structure, and has strong implications in processing as well as on the morphology/structure of the membranes and the catalyst layers.

This research focuses on durable, high-performance materials and interfaces for advanced water splitting, enabling a clear pathway for achieving <$2/KgH2 (on scale) via anion exchange membrane (AEM)-based electrolysis. We aim to advance this goal via an improved fundamental understanding of both hydrogen and oxygen evolution reactions (HER/OER) leading to platinum group metal (PGM)-free catalyst materials. Here, we use NiFeCo and NiMo as OER and HER catalysts, respectively, in a full alkaline electrolysis cell. A thermally stable, multi-cation AEM is used to operate the cell at elevated temperatures thereby lowering the operating potential by increasing the kinetics of the respective catalytic reactions. The transition metal catalysts, paired with this novel AEM, have been used to achieve an operating potential of 1.79 V at 1 A/cm2. This potential is 300 mV lower than similar electrolysis cells equipped with PGM-based catalysts. We have also demonstrated the efficacy of the less caustic potassium carbonate solution as a replacement for potassium hydroxide as an electrolyte. By using a carbonate-based electrolyte, the hydroxide ion required for the anodic reaction is continuously replenished by re-establishing an equilibrium with water. This consideration, coupled with the reduced alkalinity of the carbonate solution, yields an electrolysis cell capable of sustained operation with minimal increase in operating potential.

Coatings play key roles in solid oxide fuel cell (SOFC) stack durability. For example, diffusion barrier coatings on Cr-containing interconnect and balance of plant (BOP) components protect electrodes from Cr poisoning over the long operational lifetimes (>10,000 hours) of the fuel cell stack. Common defects in coatings, such as cracks, pinholes, and porosity, result in a failure to protect the electrodes, resulting in shorter operational lifetime and thus higher cost. It is very unlikely, even in the best coating process, that all these defects can be mitigated, hence identifying critical defects in parts, and removing defective parts from production before they can damage the stack, becomes paramount. Furthermore, these quality control techniques must be operational in the production/assembly line (in-line), i.e., high throughput and non-destructive, and cost effective. Redox Power Systems, LLC (Redox) together with the National Renewable Energy Laboratory (NREL) developed much needed high throughput, in-line metrology techniques for protective coatings. The overall goal of the project is to lower cost while increasing robustness, reliability, and endurance of SOFC stacks. To accomplish this, we had several objectives, including: to identify key coating and substrate defects that lead to coating failure through the use of detailed characterization methods (e.g., microscopy, XRD, EDS, electrochemistry); to assess capabilities of in-line metrology techniques, e.g., optical profilometry (Redox) and thermography (NREL), to probe these defects, or evidence thereof; demonstrate long-term performance of “defect-free” protective coatings, as identified by in-line metrology, in solid oxide fuel cell (SOFC) stack operation. In the first part of this project, the ability to identify key defects expected to lead to coating and SOFC degradation using in-line metrology tools were evaluated. Coated interconnect samples with controlled defect types and populations were tested under conditions similar to SOFC operation, followed by detailed post-test analysis to reveal the defects responsible for observed degradation. In the second part of the project, the optimal in-line metrology techniques and methodologies were used to map the defect distribution in full-size interconnects with critical defects intentionally allowed to exist in some cases. These interconnects underwent SOFC testing for extended periods (up to ~3,000 hours) followed by post-test analysis to evaluate the effectiveness of in-line metrology techniques in mitigating MCO coating related degradation. Key accomplishments in this project included the following: Demonstrated ASR of < 0.05 ohm-cm2 at 650 °C for 1,000 hours with low defect (determined by in-line metrology) interconnect samples (average ASR=37 milliohms-cm2 after over 1,000 hours). Demonstrated that low defect coatings on interconnects (as screened using in-line metrology) have low volatilization of chromium at ~650 °C for 1,000 hours as detected using Cr-getter material (< 5 at% increase above baseline); 1022 hour duration tests under humidified, elevated temperature (750 °C rather than 650 °C) compared a base case against different coating thicknesses. Demonstrated capability to identify initial key defects of interest with in-line metrology techniques using up to 8 cm by 10 cm having coatings with and without intentional defects of interest using thermal imaging and optical profilometry. Correlated key defects identified using metrology techniques with observed coating performance (e.g., ASR and Cr volatility). Conducted several 4 cm by 4 cm cell tests using MCO-interconnects that were pre-screened using some of the metrology techniques developed in the project (e.g., optical profilometry). An analysis of ASR measurements were able to show that defect-free coatings resulted in the anticipated performance in the cell tests.

Low-temperature polymer electrolyte membrane water electrolyzers (PEMWE) are an attractive clean energy technology to produce hydrogen (H2) which is an energy carrier for several applications such as transportation and grid-scale energy storage and distribution (as supported by the US Department of Energy's H2@Scale initiative). A critical component of PEMWE membrane electrode assemblies (MEA) is the catalyst layer -- composed of catalyst particles and ionomer, a binder for the catalyst and a proton conducting medium -- where the electrochemical reactions occur. The microstructure of the catalyst layer is well-known to play a key role in MEA performance by affecting critical properties such as catalyst utilization, proton conductivity, and gas transport. The evolution of the structure of the catalyst layer is strongly affected by the fabrication process, which is commonly fabricated by solution processing an ink. The microstructure and rheological properties of the inks play an important role in the evolution of final structure of the catalyst layer by affecting the processing behavior during the fabrication. In this talk, the effects of ionomer equivalent weight (EW) and dispersion media composition on the microstructure and rheological behavior of the catalyst inks will be presented. The effects on the structure and rheology of neat ionomer dispersions (with no catalyst) will also be discussed, both to gain sights into the catalyst-ionomer interactions and the rheological behavior, and their significance in membrane fabrication. The ink consists of unsupported iridium oxide (IrO2) catalyst particles and 3M ionomer dispersed in a mixture isopropanol and water. A combination of rheology and ultra small-angle X-ray scattering (USAXS) techniques were primarily used to characterize the microstructure. Preliminary findings show that ionomer stabilizes the agglomerated structure of catalyst dispersions. Reducing the ionomer EW and the alcohol fraction in the dispersion media, for any given EW, decreases the agglomerated structure of the catalyst as well as of the ionomer dispersions (with no catalyst) suggesting dominant electrostatic repulsions between the particles/ionomer at these conditions.

Battery electric vehicles possess great potential for decreasing lifecycle costs in medium-duty applications, a market segment currently dominated by internal combustion technology. Characterized by frequent repetition of similar routes and daily return to a central depot, medium-duty vocations are well positioned to leverage the low operating costs of battery electric vehicles. Unfortunately, the range limitation of commercially available battery electric vehicles acts as a barrier to widespread adoption. This paper describes the National Renewable Energy Laboratory's collaboration with the U.S. Department of Energy and industry partners to analyze the use of small hydrogen fuel-cell stacks to extend the range of battery electric vehicles as a means of improving utility, and presumably, increasing market adoption. This analysis employs real-world vocational data and near-term economic assumptions to (1) identify optimal component configurations for minimizing lifecycle costs, (2) benchmark economic performance relative to both battery electric and conventional powertrains, and (3) understand how the optimal design and its competitiveness change with respect to duty cycle and economic climate. It is found that small fuel-cell power units provide extended range at significantly lower capital and lifecycle costs than additional battery capacity alone. And while fuel-cell range-extended vehicles are not deemed economically competitive with conventional vehicles given present-day economic conditions, this paper identifies potential future scenarios where cost equivalency is achieved.