The application of hydrogen proton exchange membrane fuel cells (PEMFC) in greenhouse gas emission free heavy-duty vehicles requires extremely durable PEMFC components with service lives in the range of 30,000 h. Hence suitable test and analysis methods are required that reflect realistic operation scenarios, but significantly accelerate aging. For this purpose, a dynamic accelerated stress test was developed, which is coupled with a comprehensive in-depth in-situ and ex-situ analysis program to determine the aging processes of a PEMFC membrane electrode assembly (MEA). The test comprehends dynamic cycling between low, moderate and high load, different temperature and humidity conditions as well as recovery sequences to distinguish between reversible and irreversible failure modes. All phases of the PEMFC system (i.e. solid, liquid and gaseous) are monitored on-line during aging by sophisticated electrochemical, mass spectrometric and ion chromatographic analytical methods. The structural and elemental composition of the MEA before and after the aging program (post-mortem) are investigated by X-ray fluorescence, scanning and transmission electron microscopy. This program was able to age a commercial PEMFC to end-of-life in 1000 h, while providing an accurate picture of the aging processes involved.
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