Presently in ground vehicle industries, conducting durability tests with a high acceleration factor have become increasingly demanding for the less time and cost involvement. In the previous work, to accelerate the field test, the standard ‘test tailoring’ approach has been modified due to the requirement of high acceleration factors and the limitations of testing implementation. In this study, a computer-aided testing method is developed for the validation of this modified approach. Hence, a new test-piece has been designed by a conjugative approach involving the finite element technique and fatigue analysis. Afterwards, the accelerated durability loading profiles synthesized via the modified approach have been applied on the designed test-piece and the fatigue life has been simulated to verify the effectiveness of those loading profiles. Simulation results show that loading profiles with an acceleration factor up to 330 can be successfully generated with an accuracy of 95% by this modified approach.

Presently in ground vehicle industries, conducting durability tests with a high acceleration factor have become increasingly demanding for the less time and cost involvement. In the previous work, to accelerate the field test, the standard ‘test tailoring’ approach has been modified due to the requirement of high acceleration factors and the limitations of testing implementation. In this study, a computer-aided testing method is developed for the validation of this modified approach. Hence, a new test-piece has been designed by a conjugative approach involving the finite element technique and fatigue analysis. Afterwards, the accelerated durability loading profiles synthesized via the modified approach have been applied on the designed test-piece and the fatigue life has been simulated to verify the effectiveness of those loading profiles. Simulation results show that loading profiles with an acceleration factor up to 330 can be successfully generated with an accuracy of 95% by this modified approach.

Accelerated durability testing of automotive components has become a major interest as it may predict the life characteristics of the vehicle by testing fatigue failure at higher stress level within a shorter period of time. In this work, a specially designed sub-scaled experimental testing bed with the rigid and elastic supports of a simply supported beam was designed and built to compare the effects of the elastic foundation on the change of modal parameters of the tested structure which was later used to tune the FE model. Afterwards, the accelerated loading profiles of both sine sweep and random vibration were applied on the FE model to compare the deviation of the cumulative fatigue damage between the elastic and rigid supports. This work reveals a significant amount of inaccuracy in the current laboratory testing system where the dynamic properties of the tested structure are not maintained close to the real situation. / October 2016

Cycling of the relative humidity (RH) levels in the reactant streams of polymer electrolyte membrane (PEM) fuel cells has been reported to decay fuel cell performance. This study focuses on the accelerated durability testing to examine different modes of membrane failure via RH cycling. A single PEM fuel cell with an active area of 42.25 cm2 was tested. A Greenlight G50 test station was used to establish baseline cell (Run 1) performance with 840 hours of degradation under high-humidity idle conditions at a constant current density of 10 mA cm-2. Under the same conditions, two other experiments were conducted by varying the RH. For the H2-air RH cycling test (Run 2), anode and cathode inlet gases were provided as dry and humidified gases. Another RH cycling experiment was the H2 RH cycling test (Run 3): the anode inlet gas was cycled whereas keeping the other side constantly at full humidification. These two RH cycling experiments were alternated in dry and 100% humidified conditions every 10 and 40 minutes, respectively. In the experiments, the fuel cells contained a GoreTM 57 catalyst coated membrane (CCM) and 35 BC SGL gas diffusion layers (GDLs). The fuel cell test station had been performed under idle conditions at a constant current density of 10 mA cm-2. Under the idle conditions, operating at very low current density, a low chemical degradation rate and minimal electrical load stress were anticipated. However, the membrane was expected to degrade due to additional stress from the membrane swelling/contraction cycle controlled by the RH. In this work the performance of the 100% RH humidified cell (Run 1) was compared with that of RH cycling cells (Run 2 and Run 3). Chemical and mechanical degradation of the membrane were investigated using in-situ and ex-situ diagnostic methods. The results of each measurement during and after fuel cell operation are consistent. They clearly show that changing in RH lead to an overall PEM fuel cell degradation due to the increase in membrane degradation rate from membrane resistance, fluoride ion release concentration, hydrogen crossover current, membrane thinning, and hot-spot/pin-hole formation.

Cycling of the relative humidity (RH) levels in the reactant streams of polymer electrolyte membrane (PEM) fuel cells has been reported to decay fuel cell performance. This study focuses on the accelerated durability testing to examine different modes of membrane failure via RH cycling. A single PEM fuel cell with an active area of 42.25 cm2 was tested. A Greenlight G50 test station was used to establish baseline cell (Run 1) performance with 840 hours of degradation under high-humidity idle conditions at a constant current density of 10 mA cm-2. Under the same conditions, two other experiments were conducted by varying the RH. For the H2-air RH cycling test (Run 2), anode and cathode inlet gases were provided as dry and humidified gases. Another RH cycling experiment was the H2 RH cycling test (Run 3): the anode inlet gas was cycled whereas keeping the other side constantly at full humidification. These two RH cycling experiments were alternated in dry and 100% humidified conditions every 10 and 40 minutes, respectively. In the experiments, the fuel cells contained a GoreTM 57 catalyst coated membrane (CCM) and 35 BC SGL gas diffusion layers (GDLs). The fuel cell test station had been performed under idle conditions at a constant current density of 10 mA cm-2. Under the idle conditions, operating at very low current density, a low chemical degradation rate and minimal electrical load stress were anticipated. However, the membrane was expected to degrade due to additional stress from the membrane swelling/contraction cycle controlled by the RH. In this work the performance of the 100% RH humidified cell (Run 1) was compared with that of RH cycling cells (Run 2 and Run 3). Chemical and mechanical degradation of the membrane were investigated using in-situ and ex-situ diagnostic methods. The results of each measurement during and after fuel cell operation are consistent. They clearly show that changing in RH lead to an overall PEM fuel cell degradation due to the increase in membrane degradation rate from membrane resistance, fluoride ion release concentration, hydrogen crossover current, membrane thinning, and hot-spot/pin-hole formation.

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.

Fuel cells are known for their high efficiency and have the potential to become a major technology for producing clean energy, especially when the fuel, e.g. hydrogen, is produced from renewable energy sources such as wind or solar. Currently, the two main obstacles to wide-spread commercialization are their high cost and the short operational lifetime of certain components. Polymer electrolyte membrane (PEM) fuel cells have been a focus of attention in recent years, due to their use of hydrogen as a fuel, their comparatively low operating temperature and flexibility for use in both stationary and portable (automotive) applications. Perfluorosulfonic acid membranes are the leading ionomers for use in PEM hydrogen fuel cells. They combine essential qualities, such as high mechanical and thermal stability, with high proton conductivity. However, they are expensive and currently show insufficient chemical stability towards radicals formed during fuel cell operation, resulting in degradation that leads to premature failure. The incorporation of durability improving additives into perfluorosulfonic acid membranes is discussed in this work. iv Cerium oxide (ceria) is a well-known radical scavenger that has been used in the biological and medical field. It is able to quench radicals by facilely switching between its Ce(III) and Ce(IV) oxidation states. In this work, cerium oxide nanoparticles were added to perfluorosulfonic acid membranes and subjected to ex-situ and in-situ accelerated durability tests. The two ceria formulations, an in-house synthesized and commercially available material, were found to consist of crystalline particles of 2 – 5 nm and 20 – 150 nm size, respectively, that did not change size or shape when incorporated into the membranes. At higher temperature and relative humidity in gas flowing conditions, ceria in membranes is found to be reduced to its ionic form by virtue of the acidic environment. In ex-situ Fenton testing, the inclusion of ceria into membranes reduced the emission of fluoride, a strong indicator of degradation, by an order of magnitude with both liquid and gaseous hydrogen peroxide. In open-circuit voltage (OCV) hold fuel cell testing, ceria improved durability, as measured by several parameters such as OCV decay rate, fluoride emission and cell performance, over several hundred hours and influenced the formation of the platinum band typically found after durability testing.