Carbon corrosion is an important degradation mechanism that can impair PEMFC performance through the destruction of catalyst connectivity, collapse of the electrode pore structure, loss of hydrophobic character, and an increase of the catalyst particle size. In this study, carbon corrosion was quantified in situ by measurement of carbon dioxide in the fuel cell exhaust gases through non-dispersive infrared spectroscopy during simulated drive cycle operations consisting of potential cycling with varying upper and lower potential limits. These studies were conducted for three different types of carbon supports. A reduction in the catalyst layer thickness was observed during a simulated drive cycle operation with a concomitant decrease in catalyst layer porosity, which led to performance losses due to increased mass transport limitations. The observed thickness reduction was primarily due to compaction of the catalyst layer, with the actual mass of carbon oxidation (loss) contributing only a small fraction (< 20%). The dynamics of carbon corrosion are presented along with a model that simulates the transient and dynamic corrosion rates observed in our experiments. Accelerated carbon corrosion stress tests are presented and their effects are compared to those observed for the drive cycle test.

An electrochemical flow cell system with catalyst-ionomer ink deposited on glassy carbon is used to investigate the aqueous stability of commercial PtCo alloys under cyclic potentials. An on-line inductively coupled plasma-mass spectrometer, capable of real-time measurements, is used to resolve the anodic and cathodic dissolution of Pt and Co during square-wave and triangle-wave potential cycles. We observe Co dissolution at all potentials, distinct peaks in anodic and cathodic Pt dissolution rates above 0.9 V, and potential-dependent Pt and Co dissolution rates. The amount of Pt that dissolves cathodically is smaller than the amount that dissolves anodically if the upper potential limit (UPL) is lower than 0.9 V. At the highest UPL investigated, 1.0 V, the cathodic dissolution greatly exceeds the anodic dissolution. A non-ideal solid solution model indicates that the anodic dissolution can be associated with the electrochemical oxidation of Pt and PtOH to Pt²⁺, and the cathodic dissolution to electrochemical reduction of a higher Pt oxide, PtO_x (x > 1), to Pt²⁺. Pt also dissolves oxidatively during the cathodic scans but in smaller amounts than due to the reductive dissolution of PtO_x. The relative amounts Pt dissolving oxidatively as Pt and PtOH depend on the potential cycle and UPL.