Development and Scale Up of Enhanced ORR Pt‐based Catalysts for PEMFCs

HySA/Catalysis has developed Pt‐only materials supported on Vulcan and Ketjenblack carbon, at various Pt loadings in the form of the HySA‐V and HySA‐K series of catalysts. These materials have been proven on both an ex‐situ (TF‐RDE techniques) and in situ (single cell MEA testing) basis to be on par with state‐of‐the‐art commercial benchmark materials. Despite these development achievements high‐performance platinum alloy catalysts that address sluggish oxygen reduction reaction (ORR) kinetics are required in order to minimize the precious metal content and ultimately the cost of fuel cell catalysts. Conveyed in this paper is a systematic investigation of the effect of alloying counterpart deposition sequence on the electrochemical and physical properties of the dealloyed class of advance ORR catalysts at a laboratory synthesis scale. Progression from laboratory scale synthesis to pre‐commercial production is presented and in‐situ single cell performance of scaled dealloyed catalyst materials is given.