Graphitized carbon support for enhanced durability and mitigation of reversal degradation in proton exchange membrane fuel cells

Proton exchange membrane fuel cells (PEMFCs) encounter durability challenges during startup/shutdown (SUSD) cycles and cell reversal, where carbon corrosion accelerates the catalyst degradation. In this study, commercial Ketjen Black EC-300J was graphitized at 1800–2600^oC and evaluated as corrosion-resistant supports for Pt catalysts. Accelerated stress test (AST) simulating SUSD cycling following U.S. Department of Energy (DOE) protocols (triangle wave voltage cycling between 1.0 and 1.5 V, 5000 cycles) demonstrated that 2600^oC-graphitized EC-300J (GEC26) exhibited outstanding corrosion resistance. Pt/GEC26 exhibited minimal voltage loss of 12 mV, with corresponding electrochemical surface area (ECSA) loss of only 29.61 % after AST, fulfilling DOE durability targets. Under cell reversal conditions, Pt/GEC26 extended sustainable reversal operation time to 212 s, four times longer than Pt/EC300, and decreased the normalized degradation rate by 61 % (from 36 to 14 mV min⁻¹). These durability improvements arise from highly ordered graphitic structures with increased sp²-carbon content and lower defect density, which intrinsically enhance corrosion resistance. Moreover, the increased hydrophobicity of GEC26 promotes efficient water removal, mitigating water-facilitated carbon corrosion during reversal. This work highlights the industrially compatible graphitization strategy as a promising approach for developing durable PEMFC catalysts under SUSD and cell reversal, integrating fundamental materials science with next-generation automotive PEMFCs technology demands.