Enhanced Performance and Durability of Proton Exchange Membrane Fuel Cell Catalyst Supports via Nanodrilling-Induced Selective Mesoporous Carbon Structures

Proton exchange membrane fuel cells (PEMFCs) are efficient, low-emission energy sources for vehicles and backup power. The membrane electrode assembly is crucial for performance; however, traditional porous carbon supports used for catalysts suffer from corrosion, particularly during start-up and shut-down cycles, which limits fuel cell durability. In this study, we investigated the effect of nanodrilling on the performance and durability of carbon supports in PEMFCs. Two commercial carbon blacks were physically activated and subjected to nanodrilling treatment using Ni to selectively introduce mesopores. The resulting materials were characterized by a combination of analytical methods, including N 2 adsorption–desorption isotherm curves, X-ray diffraction, and electron microscopy. Furthermore, half- and full-cell evaluations were conducted to assess the electrochemical performance and durability of the modified carbon supports. The results indicate that nanodrilling effectively introduces mesopores, enhances crystallinity, and improves both the initial performance and durability of the catalyst supports. The enhanced performance is attributed to the improved catalyst dispersion and reduced carbon corrosion facilitated by the selective mesopore structure. This study highlights the potential of nanodrilling as a promising strategy for the development of high-performance and durable carbon supports for PEMFC applications.