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Proton Exchange Membrane (PEM) fuel cell electrodes with different ionomer contents were studied with various microscopic techniques. The morphology and surface potential were examined by Atomic Force Microscopy (AFM) and Kelvin Probe Microscopy (KPM), respectively. The particulate nature of the electrode was well displayed in the topography and phase images. The particle and pore size (Z) distributions showed the most frequent values at 30–40 nm and 20–30 nm, respectively. The particle size corresponds to the size of the carbon support for the platinum catalyst. Catalyst agglomeration was observed in high ionomer content electrodes. The surface potential images showed distinct difference to the topography images. The overall grain size was seen to increase, the pore volume to decrease, the surface roughness to decrease, and the surface potential variation to increase with the increase of ionomer content in the catalyst layer. Transmission electron microscopy (TEM) was carried out on selective electrodes to provide additional information and confirmed with the AFM results. Cyclic voltammetry (CV) showed that the electrode containing 30 wt.% ionomer has maximum catalyst utilization. [ABSTRACT FROM AUTHOR]

A family of novel carbon materials with intermediate surface area and varying morphology and surface chemistry were used to prepare Pt/C catalysts by two different preparation procedures; a chemical impregnation method and a microwave-assisted polyol method. The catalysts were thoroughly characterized, and their electrochemical performance and stability were investigated with rotating disc electrode (RDE) cyclic voltammetric (CV) measurements. The intermediate-surface-area carbon supports gave catalysts with much greater support stability than a widely used standard catalyst. The novel catalysts had lower electrochemical surface area than the reference, but their specific electrocatalytic activity towards the oxygen-reduction reaction (ORR) was much higher, and some of them also featured higher mass-specific ORR activity than the reference. The series of catalysts prepared by the microwave-assisted polyol method featured smaller Pt nanoparticles and higher activities than those prepared by impregnation. On the other hand, the impregnated catalysts showed better durability of the Pt particles. The most promising catalysts were selected and elaborated in further optimized preparation procedures to obtain quantities sufficient for their use in proton-exchange membrane fuel cells (PEMFCs). [ABSTRACT FROM AUTHOR]