Lithium-ion batteries are a leading candidate for electric vehicle and smart grid applications. However, further optimizations of the energy/power density, coulombic efficiency and cycle life are still needed, and this requires a thorough understanding of the dynamic evolution of each component and their synergistic behaviors during battery operation. With the capability of resolving the structure and chemistry at an atomic resolution, advanced analytical transmission electron microscopy (AEM) is an ideal technique for this task. The present review paper focuses on recent contributions of this important technique to the fundamental understanding of the electrochemical processes of battery materials. A detailed review of both static (ex situ) and real-time (in situ) studies will be given, and issues that still need to be addressed will be discussed.

The recent release of hydrogen economy roadmaps for several major countries emphasizes the need for accelerated worldwide investment in research and development activities for hydrogen production, storage, infrastructure and utilization in transportation, industry and the electrical grid. Due to the high gravimetric energy density of hydrogen, the focus of technologies that utilize this fuel has recently shifted from light-duty automotive to heavy-duty vehicle applications. Decades of development of cost-effective and durable polymer electrolyte membrane fuel cells must now be leveraged to meet the increased efficiency and durability requirements of the heavy-duty vehicle market. This Review summarizes the latest market outlooks and targets for truck, bus, locomotive and marine applications. Required changes to the fuel-cell system and operating conditions for meeting Class 8 long-haul truck targets are presented. The necessary improvements in fuel-cell materials and integration are also discussed against the benchmark of current passenger fuel-cell electric vehicles.

Significant mass-transport resistances in polymer-electrolyte-fuel-cell catalyst layers (CLs) impose a lower limit on Pt-loading levels, hindering wide-spread fuel-cell commercialization. The origin of this resistance remains unclear. Minimization of CL mass-transport resistance is imperative to achieve better CL design and performance. In this paper, an operando method based on H2 limiting current is used to characterize and quantify CL resistance in traditional porous Pt/carbon-based electrodes. CL sub-resistances are isolated using continuum multiscale modeling and experiments, investigating the effects of reactant molecular weight, pressure, and ionomer to carbon weight ratio. The results expose CL resistance including both interfacial and transport components, although the majority of the CL resistance is ascribed to a local resistance close to the Pt reaction sites, which includes interfacial resistance and local transport resistance. Variations in temperature, humidity, and primary particle loading (Pt:C ratio) highlight the impact of operating conditions and CL design parameters on CL sub-resistances. The observed trends guide optimization of CL design to achieve novel low-loaded fuel-cell electrodes.

Platinum-based alloys are known to demonstrate advanced properties in electrochemical reactions that are relevant for proton exchange membrane fuel cells and electrolyzers. Further development of Pt alloy electrocatalysts relies on the design of architectures with highly active surfaces and optimized utilization of the expensive element, Pt. Here, we show that the three-dimensional Pt anisotropy of Pt-Ni rhombic dodecahedra can be tuned by controlling the ratio between Pt and Ni precursors such that either a completely hollow nanoframe or a new architecture, the excavated nanoframe, can be obtained. The excavated nanoframe showed ∼10 times higher specific and ∼6 times higher mass activity for the oxygen reduction reaction than Pt/C, and twice the mass activity of the hollow nanoframe. The high activity is attributed to enhanced Ni content in the near-surface region and the extended two-dimensional sheet structure within the nanoframe that minimizes the number of buried Pt sites.

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. While the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

In situ electrochemical diagnostics designed to probe ionomer interactions with platinum and carbon were applied to relate ionomer coverage and conformation, gleaned from anion adsorption data, with O₂ transport resistance for low-loaded (0.05 mg_Pt cm^-2) platinum-supported Vulcan carbon (Pt/Vu)-based electrodes in a polymer electrolyte fuel cell. Coupling the in situ diagnostic data with ex situ characterization of catalyst inks and electrode structures, the effect of ink composition is explained by both ink-level interactions that dictate the electrode microstructure during fabrication and the resulting local ionomer distribution near catalyst sites. Electrochemical techniques (CO displacement and ac impedance) show that catalyst inks with higher water content increase ionomer (sulfonate) interactions with Pt sites without significantly affecting ionomer coverage on the carbon support. Surprisingly, the higher anion adsorption is shown to have a minor impact on specific activity, while exhibiting a complex relationship with oxygen transport. Ex situ characterization of ionomer suspensions and catalyst/ionomer inks indicates that the lower ionomer coverage can be correlated with the formation of large ionomer aggregates and weaker ionomer/catalyst interactions in low-water content inks. These larger ionomer aggregates resulted in increased local oxygen transport resistance, namely, through the ionomer film, and reduced performance at high current density. In the water-rich inks, the ionomer aggregate size decreases, while stronger ionomer/Pt interactions are observed. The reduced ionomer aggregation improves transport resistance through the ionomer film, while the increased adsorption leads to the emergence of resistance at the ionomer/Pt interface. Overall, the high current density performance is shown to be a nonmonotonic function of ink water content, scaling with the local gas (H₂, O₂) transport resistance resulting from pore, thin film, and interfacial phenomena.

Control of structure at the atomic level can precisely and effectively tune catalytic properties of materials, enabling enhancement in both activity and durability. We synthesized a highly active and durable class of electrocatalysts by exploiting the structural evolution of platinum-nickel (Pt-Ni) bimetallic nanocrystals. The starting material, crystalline PtNi3 polyhedra, transforms in solution by interior erosion into Pt3Ni nanoframes with surfaces that offer three-dimensional molecular accessibility. The edges of the Pt-rich PtNi3 polyhedra are maintained in the final Pt3Ni nanoframes. Both the interior and exterior catalytic surfaces of this open-framework structure are composed of the nanosegregated Pt-skin structure, which exhibits enhanced oxygen reduction reaction (ORR) activity. The Pt3Ni nanoframe catalysts achieved a factor of 36 enhancement in mass activity and a factor of 22 enhancement in specific activity, respectively, for this reaction (relative to state-of-the-art platinum-carbon catalysts) during prolonged exposure to reaction conditions.

This work describes the performance improvement of a polymer electrolyte fuel cell with a novel class of microporous layers (MPLs) that incorporates hydrophilic additives: one with 30 μm aluminosilicate fibers and another with multiwalled carbon nanotubes with a domain size of 5 μm. Higher current densities at low potentials were observed for cells with the additive-containing MPLs compared to a baseline cell with a conventional MPL, which correlate with improvements in water management. This is also observed for helium and oxygen experiments and by the lower amount of liquid water in the cell, as determined by neutron radiography. Furthermore, carbon-nanotube-containing MPLs demonstrates improved durability compared to the baseline MPL. Microstructural analyses including nanotomography demonstrate that the filler material in both the additive-containing MPLs provide preferential transport pathways for liquid water, which correlate with ex situ measurements. The main advantage provided by these MPLs is improved liquid-water removal from the cathode catalyst layer, resulting in enhanced oxygen delivery to the electrocatalyst sites.