PEMFC is the promising technology for automotive applications with a large deployment horizon by 2030. However, in view of extending their use to a broad range of customers, progress have to be done in terms of cost, performance and durability. The FURTHER-FC project aims at understanding performance limitations due to the coupling between electrochemical and transport issues in the Cathode Catalyst Layer (CCL) which is the main bottleneck for future PEMFC. The comprehensive and innovative approach is based on unique and intensive fundamental characterizations coupled with advanced modelling, from sub-micrometer to its full thickness. The analysis are performed on CCL customized with different and original materials, and will cover structural 3D analysis of the CCL, local operando diagnostics (temperature, liquid water) in the CCL, advanced characterization of ionomer films, innovative diagnostics on transport limitations, fundamental electrochemistry. Advanced one and two-phase models will be used as a sup

Current PEMFC stack technologies for automotive applications show limitations in performance, durability and production cost which are primary challenges to reach mass production and fuel cell commercialization. It is obvious that filling the gap between present State Of the Art performances and expected targets will not be possible by an incremental evolution of the present PEMFC technology as deployed today in first commercial cars. Thus, it is necessary to identify, develop and validate a more innovative, disruptive approach including new materials and processes to have a chance to reach these ambitious challenges. In this perspective, the DOLPHIN project is exploring an unconventional, highly innovative route towards a newly designed cell architecture featuring a Dual-Core Single Repeat Unit (DC-SRU). Thanks to smart approaches in the fields of ‘Process Integration’, ‘Interfaces Quality’ and ‘Materials Efficiency’, DOLPHIN will deliver a light-weight & compact fuel cell and stack architecture with low (mass/charge) transport resistances inside the fuel cell core. Mechanically strong and corrosion resistant structures with redesigned and more coherent cell-internal interfaces will delay the activation of major ageing mechanisms and failures occurrence hence increasing system reliability to a level compatible with automotive durability targets. Finally, by triggering an original concept relying on two integrated multi-functional cores and two architectures (w/o GDM) of increasing level of disruptiveness, DOLPHIN will finally deliver a reinvented process scheme with projected stack production costs less than 20 €/kW. DOLPHIN will in that sense address drastic fuel cell stack requirements for the automotive industry and beyond. It consists in another step forward toward the large-scale deployment of environmentally friendly vehicles, while also participating to the increase in European competitiveness, industrialisation and self-sufficiency in energy.

The R&D project PEMTASTIC aims to meet the key technical challenges to increase durability of MEAs for HD applications. These challenges are approached with a combination of model-based design and the development of a durable CCM using innovative materials tailored for heavy duty operation at high temperature (105°C). The quantitative targets correspond to a durability of 20,000 hours maintaining a state-of the art power density of 1.2 W/cm2@0.65 V at a Pt loading of 0.30 g/kW. Truck mission profiles will be analyzed (Symbio) in order to define relevant FC operation protocols and stressors. Degradation tests will be carried out in differential cells and will be assisted by physical-chemical material characterization to assure well defined data required for parametrization of degradation models (CEA, DLR). A combination of micro- and mesoscale models as well as 1D and 2D cell models (ZHAW, DLR) will capture the impact of material parameters on performance and durability and will address all material and CCM parameters which will be iteratively adapted by industry partners. The materials which will be implemented and adapted are advanced corrosion resistant supports (Imerys) combined with a novel catalyst deposition technique (Heraeus) to mitigate for ECSA loss. Prototype Nafion ionomers and membranes with high conductivity in dry conditions will be used (Chemours). Eventually, an improved cathode catalyst layer will be designed considering Pt particle size distribution and superior catalyst ionomer interaction (IRD). The selection of a commercial GDL will consider accommodation of a wide range of operating conditions. The final MEA and the concept of model-based MEA development will be validated in a short stack at TRL4 (Symbio). As additional outcomes, implications on system management and on the BoP components will be drawn, and the reduced computational demand for degradation modelling will facilitate fast health assessment and performance prediction.