Overall, the MORELife project aims to understand cause-and-effect relationships in heavy-duty (HD) stacks, implement innovative modeling approaches, and determine specifications for next-generation membrane electrode assemblies (MEAs) for HD applications.
Objective 1: Develop a multi-pronged approach using baseline technology to understand and mitigate durability and degradation issues of HD stack components. This includes small-scale testing and mechanistic modeling, with protocols and models for catalyst degradation. The synthesis and optimization of catalysts with reduced platinum loading, particularly the Gen 3c catalyst, led to promising performance and durability improvements. Extensive tests and post-mortem analyses were conducted to understand degradation processes. Advanced methods for real-time diagnostics and simulation of real-world driving conditions were developed.
Objective 2: Advanced experimental analyses of baseline technologies using detailed analysis, single-cell testing of small-active-area MEAs, short stack testing for systematic screening of beyond baseline MEAs, and in/ex situ characterization methods. An Accelerated Stress Test (AST) protocol was developed to test material properties, targeting copper leaching and enabling rapid durability screening. Several models, including a spatially resolved performance model for LT-PEMFC, a 1D platinum catalyst degradation model, and a bimetallic catalyst degradation model, were developed, parameterized, and validated. MEB conducted 30 syntheses of catalysts to optimize composition and size of metallic particles. The best catalysts were integrated into MEAs and tested for performance and durability. SEM and TEM images documented structural changes. Tests showed that baseline materials meet MORELife goals, while the Gen 3c catalyst showed promising results with reduced platinum loading.
Objective 3: Analyze real-world data from HD vehicles to identify predominant degradation stimuli and failure modes based on stack operation conditions and transients. Material-specific ASTs were developed to provide critical data for a global degradation model for baseline MEAs. These protocols enable rapid durability screening and improve material durability. Analysis of real vehicle data provided insights into degradation stimuli and failure modes, which were used to develop AST protocols. Results were integrated into the global degradation model to enhance understanding of degradation processes and improve material durability.
Objective 4: Design a beyond-baseline MEA tailored for HD applications, featuring innovative core-shell catalysts, advanced gas diffusion layers (GDLs), and reinforced membranes with tailored thickness and chemical stabilization. MEB conducted extensive synthesis and optimization of catalysts, focusing on core-shell structures to enhance performance and durability. Advanced GDLs were developed using novel hydrophobization methods without fluorinated polymers, improving system morphology and stability. Reinforced membranes were designed with tailored thickness and chemical stabilization to withstand harsh conditions. Integration of these components into MEAs was tested for performance and durability, showing promising results with reduced platinum loading and improved stability. This comprehensive approach contributed to a highly durable and efficient MEA for HD applications.
