The impact of ink processing on key characteristics of platinum detachment and pore structure to optimize fuel cell performance

Proton exchange membrane fuel cells (PEMFCs) convert chemical into electrical energy, making them promising for various applications. Understanding the interdependencies of processing steps along the catalyst coated membrane manufacturing process is crucial for optimizing performance. This study analyzes the entire process chain, including ink processing through magnetic stirring, ultrasonic sonication and wet impact milling, as well as the coating and characterization of the catalyst layer and its electrochemical performance. Findings indicate that particle size distribution, pore structure, and the detachment of platinum (Pt) from the Pt/carbon black (CB) catalyst significantly impact PEMFC performance. While magnetic stirring and ultrasonic sonication minimize Pt detachment, they lead to a broad particle size distribution and denser catalyst layers. Conversely, wet impact milling reduces Pt/CB particle size and promotes an optimal pore structure but also results in some Pt detachment. These results highlight the need to understand and optimize processing conditions to enhance PEMFC efficiency. • Platinum acts as a catalyst in proton exchange membrane fuel cells. • Energy input can detach platinum from carbon support. • Platinum agglomerates reduce catalytic activity. • Pore structure is key for effective mass transport. • Optimized processing improves PEMFC performance and longevity.