Cette thèse réalisée dans le cadre des projets PIE CNRS AMELI-0Pt et AMEPlas et ANR AMADEUS a regroupé plusieurs entités autour de la thématique des piles à combustible : Dreux Agglomération puis l’Agence Innovation Made In Dreux (MID), le GREMI, le LACCO et initialement l’industriel MHS Equipment. L’objectif de ce travail est l’élaboration par voie plasma et l’optimisation d’électrodes de piles à combustible de type PEMFC et SAMFC dans le but d’obtenir de bonnes performances avec des charges de platine ultra faibles ou sans platine. Le projet a été organisé en quatre étapes : l’étude de la croissance simultanée de platine et de carbone co-pulvérisés par plasma, la dispersion optimale de quantités ultra faibles de catalyseur, le remplacement du platine par un alliage bimétallique à base de palladium, et le dépôt direct du catalyseur sur la membrane par plasma. En utilisant un faisceau synchrotron de rayons X (Synchrotron SOLEIL), en collaboration avec le CRMD, l’étude GISAXS des couches minces Pt-C co-pulvérisés a révélé l’organisation particulière du platine dans ce type de nanostructure. Ces couches minces Pt-C offrent d’excellentes performances (20 kW.gPt-1) avec des charges de platine ultra faibles. Des électrodes PdPt (5 %at Pt) faiblement chargées permettent d’atteindre de bonnes performances en PEMFC quasiment sans platine (12,5 kW.gPd-1 et 250 kW.gPt-1). L’étude de l’activité de catalyseurs PdAu vis-à-vis de l’oxydation du glycérol a révélé l’origine des effets synergiques du palladium et de l’or en milieu alcalin. Le dépôt plasma direct de platine associé ou non au dépôt de carbone sur membrane a été optimisé. Les performances obtenues avec des CCM (Catalyst Coated Membrane) plasma démontrent l’intérêt de ce type d’architecture. / This research work has been achieved in the context of the PIE CNRS AMELI-0Pt and AMEPlas and ANR AMADEUS projects and has gathered several entities around the Fuel Cell research: Dreux Agglomération and Agence Innovation Made In Dreux (MID), the French national research laboratories GREMI and LACCO and initially the company MHS Equipment. The project aims at developing and optimising fuel cell electrodes (anode and cathode) for PEMFC (Proton Exchange Membrane Fuel Cell) and SAMFC (Solide Alkaline Membrane Fuel Cell) entirely by plasma in order to reach effective performances with ultra low platinum loadings or none at all. The project was divided into four stages: the study of the simultaneous growth of platinum and carbon co-sputtered by plasma, the optimum dispersion of a very small amount of catalysts, the replacement of platinum by a palladium based bimetallic alloy, and the direct deposition of the catalyst on the polymer membrane by plasma sputtering. By using an X-ray synchrotron beam light source (SOLEIL Synchrotron), in collaboration with the CRMD, the GISAXS study of co-sputtered Pt-C thin films has revealed the particular organisation of platinum inside this type of nanostructure. These Pt-C thin films offer excellent performances (20 kW.cm-2) with ultra low platinum amounts. Low loaded PdPt (5 %at Pt) electrodes offered good performances almost without platinum (12,5 kW.gPd-1 et 250 kW.gPt-1). The study of the activity of PdAu catalysts (plasma sputtered) on the glycerol electro-oxidation revealed the origin of the synergistic effects of palladium and gold in an alkaline medium. The direct plasma deposition of platinum associated or not with carbon deposition on membrane has been optimised. The performances of the plasma prepared CCM (Catalyst Coated Membrane) demonstrate the potential of this type of architecture.

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Philosophiae Doctor - PhD / The widespread use of fossil energy has been most convenient to the world, while they also cause environmental pollution and global warming. Therefore, it is necessary to develop clean and renewable energy sources, among which, hydrogen is considered to be the most ideal choice, which forms the foundation of the hydrogen energy economy, and the research on hydrogen production and fuel cells involved in its production and utilization are naturally a vital research endeavor in the world. Electrocatalysts are one of the key materials for proton exchange member fuel cells (PEMFCs) and water splitting. The use of electrocatalysts can effectively reduce the reaction energy barriers and improve the energy conversion efficiency.

Proton-Exchange Membrane Fuel Cells are an alternative source of electricity generation for automobiles and stationary power plants. With increasing concerns on environmental issues, recent research has focused on maximizing the efficiency and durability as well as minimizing the costs of fuel cells. One of the main areas of research is optimizing the structure of the cathode catalyst layer. The main driving force of this thesis was the effective visualization of nanostructure of the ionomer, which is responsible for proton conduction in the cathode catalyst layer. However, challenges regarding sample preparation and radiation damage still need to be well understood. Different sample preparation techniques of catalyst inks and catalyst coated membranes were used for Scanning and Transmission Electron Microscopy, such as freeze fracturing, ultramicrotomy and Focused Ion Beam. Comparisons of the microstructure and chemical differences of all components, especially the ionomer, prepared by ultramicrotomy and Focused Ion Beam, was done with Transmission Electron Microscopy and Scanning Transmission X-ray Microscopy applied to the same catalyst coated membrane sample. Detailed spectroscopic information regarding components in both specimens was compared with C 1s and F 1s near edge X-ray absorption spectra recorded in a Scanning Transmission X-ray Microscope. Focused Ion Beam causes extensive damage to the carbon support and ionomer but prepares thinner sections than ultramicrotomy. This work makes it possible to understand the limitations of each sample preparation and compositional analysis technique in order to later apply one of them to image the ionomer in the catalyst layer at the nanoscale, hopefully using tomography techniques. / Thesis / Master of Materials Science and Engineering (MMatSE)

Indiana University-Purdue University Indianapolis (IUPUI) / Proton exchange membrane fuel cells (PEMFC’s) offer an attractive alternative energy resource over traditional fossil fuels. The advantages such as high power density, relatively quick start-up, rapid response to varying loads and low operating temperatures make it a preferred technology option compared to other alternative energy sources. Nafion® by DuPont plays an integral role in the success of PEM fuel cells due to its high proton conductivity and high chemical and thermal stability. This research project aims to study the effect of mechanical and hygro-thermal stresses on the mechanical performance and proton conductivity of the membrane by subjecting it to realistic operating conditions such as those encountered in an automobile. In this thesis, the time-dependent behavior of the membrane has been modeled using a Prony series and the change in the conductivity due to mechanical loading was experimentally measured. The modeling of both electrochemical and mechanical properties can further be used in studying the degradation properties of the membrane and should guide the development of better membrane materials. Visco-elastic stress relaxation theory has been used in modeling the time-dependent behavior of the specimen. The EIS spectrum has been analyzed using a non-linear least squares method and an equivalent circuit method was also used to fit the spectra. This project was conducted in three phases. In the first phase a novel test facility was built to perform the experiments. A conductivity measurement test cell that measured the proton conductivity of a membrane was modeled and manufactured. The second phase included the design of different experiments that helped in modeling the interdependence of electrochemical and mechanical properties of the membrane. In this process, three series of experiments that tested the electrochemical and mechanical properties of the specimen were conducted. The membrane was held at constant strain and the through plane impedance was measured at different times during the test, specifically before and after stretching at ambient and varying environmental conditions. The membrane was also subjected to both mechanical and hygro-thermal loading conditions during the test. In the third phase, time-dependant mathematical model for the changes in the material properties were developed. The experimental apparatus thus tested the mechanical and electrochemical properties of the membrane simultaneously while the specimen was being subjected to constant mechanical and varying hygro-thermal conditions. Since the testing method is a novel procedure, the reliability and repeatability of the experimental facility has been verified before conducting the experiments. The experimental apparatus can further be used to test the membrane at varying strain rates and different hygro-thermal loading conditions in a consistent manner. The model developed can be used to analyze the degradation behavior of membrane and also to build better fabrication methods and membrane materials in future.

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In this dissertation, novel approaches to PEMFC durability research are summarized. These efforts are significantly different from most other studies on durability in that rather than focusing on chemical degradation, more attention is given to the mechanical aspects of the PEMFC system. The tensile stress-strain behavior of Nafion® 117 (N117) and sulfonated poly(arylene ether sulfone) random copolymer (BPSH35) membranes is explored under ambient conditions, with respect to the effects of initial strain rate, counterion type, molecular weight and the presence of inorganic fillers. A three-dimensional "bundle-cluster" model is proposed to interpret the tensile observations, combining the concepts of elongated polymer aggregates, proton conduction channels as well as states of water. The rationale focuses on the polymer bundle rotation/interphase chain readjustment before yielding and polymer aggregates disentanglement/ reorientation after yielding. In addition, the influence of uniaxial loading on proton conductivity of N117 and BPSH35 membranes is investigated. When the membranes are stretched, their proton conductivities in the straining direction increase compared to the unstretched films, and then relax exponentially with time. The behavior is explained on the basis of the morphological variations of hydrophilic channels, accompanied by the rotation, orientation and disentanglement of the copolymer chains in the hydrophobic domains, as illustrated with the help of our bundle-cluster model. Finally, the long-term aging of hydrogen-air PEMFCs is examined with a cyclic current profile and under constant current conditions. The end-of-period diagnosis is performed for both MEAs at 100h aging intervals, including a series of cell polarization, impedance and electrochemical experiments. The results demonstrate that hydrogen crossover is the most significant result of degradation for the MEA under cyclic aging mode due to the formation of pinholes at approximately 500-600h, and mass transport limitations are the major degradation sources for constant current mode. A phenomenological mathematical model is set up to describe the PEMFC aging process under both cyclic and constant conditions. / Ph. D.

Indiana University-Purdue University Indianapolis (IUPUI) / The innovation and investigation of catalysts in proton exchange membrane fuel cells are included in this thesis. In the first part of this work, stability of the catalyst support of PEMFC catalyst is investigated. Nanoscale platinum particles were loaded on two different kinds of carbon supports, nano graphene sheets and functionalized carbon black/graphene hybrid were developed by the liquid phase reaction. The crystal structure of two kinds of catalysts was characterized by X-ray diffractometer (XRD). The morphology and particle size were characterized by scanning electron microscope (SEM) and transmission electron microscope (TEM). Pt loading was measured by thermal gravimetric analysis (TGA). The Brunauer, Emmett and Teller (BET) method was applied to test the surface area of the catalysts. The electrochemical surface area (ECSA) and mass activity during oxygen reduction reaction (ORR) process for two kinds of catalyst were tested by cyclic voltammetry method under different conditions. The stability of the catalysts were tested by accelerated durability test (ADT). The results show that although the mass activity of Pt/graphene is much lower, the stability of it is much better than that of the commercial catalyst. After adding functionalized carbon black (FCB) as spacer, the stability of the catalyst is preserved and at the meantime, the mass activity becomes higher than 20% Pt/XC72 catalyst. The lower mass activity of both catalysts are due to the limitation of the electrolyte diffusion into the carbon support because of the aggregation nature of graphene nano-sheets. After introducing functional carbon black as spacer, the mass activity and ECSA increased dramatically which proved that FCB can be applied to prevent the restacking of graphene and hence solved the diffusion problem. In the meantime, the durability was still keeping the same as Pt/graphene catalyst. In the second part of the work, the restacking problem was solved by introducing FCB as spacers between functionalized graphene nanosheets. The same measurement was applied to test the electrochemical performance of Pt/FCB/FG catalyst. The new catalyst showed a higher mass activity compared to Pt/graphene catalyst which meant the restacking problem was partially solved. The durability of the Pt/FCB/FG catalyst was still excellent.

M. Tech. (Engineering Department Applied Electronics and Electronic Communication, Faculty of Engineering) Vaal University of Technology / This study presents the design of a proton exchange membrane fuel cell stack that can be used to replace conventional sources of electrical energy in an uninterruptible power supply system, specifically for use in the telecommunications industry. One of the major concerns regarding the widespread commercialization of fuel cells is the high cost associated with fuel cell components and their manufacturing. A fuel cell design is presented in which existing, low-cost, technologies are used in the manufacture of cell components. For example, printed circuit boards are used in the manufacturing of bipolar flow plates to significantly reduce the cost of fuel cells. The first objective was to design, construct and test a single fuel cell and small fuel cell stack in order to evaluate the use of printed circuit boards in bipolar plate manufacturing. Since the use of copper in a fuel cell environment was found to reduce the lifetime of the cells, the bipolar plates were coated with a protective layer of nickel and chrome. These coatings proved to increase the lifetime of the cells significantly. Power outputs of more than 4 W per cell were achieved. The second objective was to analyze a small fuel cell stack in order to obtain a model for predicting the performance of larger stacks. A mathematical model was developed which was then used to design an electronic circuit equivalent of a fuel cell stack. Both models were adapted to predict the performance of a fuel cell stack containing any number of cells. The models were proven to be able to accurately predict the performance of a fuel cell stack by comparing simulated results with practical performance data. Finally, the circuit equivalent of a fuel cell stack was used to evaluate the capability of a switch mode boost converter to maintain a constant voltage when driven by a fuel cell stack, even under varying load conditions. Simulation results showed the ability of the boost converter to maintain a constant output voltage. The use of supercapacitors as a replacement for batteries as a secondary energy source was also evaluated.