Accelerated Durability Testing of Fuel Cell Stacks for Commercial Automotive Applications: A Case Study

Tsuyoshi Takahashi, Takuya Ikeda, Kazuya Murata, Osamu Hotaka, Hasegawa Shigeki Hasegawa, Yuya Tachikawa, Masamichi Nishihara, Junko Matsuda, Tatsumi Kitahara, Stephen M. Lyth, Akari Hayashi, Kazunari Sasaki

Research output: Contribution to journalArticlepeer-review

39 Citations (Scopus)


System durability is crucially important for the successful commercialization of fuel cell electric vehicles (FCEVs). Conventional accelerated durability testing protocols employ relatively high voltage to hasten carbon corrosion and/or platinum catalyst degradation. However, high voltages are strictly avoided in commercialized FCEVs such as the Toyota MIRAI to minimize these degradation modes. As such, conventional durability tests are not representative of real-world FCEV driving conditions. Here, modified start-stop and load cycle durability tests are conducted on prototype fuel cell stacks intended for incorporation into commercial FCEVs. Polarization curves are evaluated at beginning of test (BOT) and end of test (EOT), and the degradation mechanisms are elucidated by separating the overvoltages at both 0.2 and 2.2 A cm-2. Using our modified durability protocols with a maximum cell voltage of 0.9 V, the prototype fuel cell stacks easily meet durability targets for automotive applications, corresponding to 15-year operation and 200,000 km driving range. These findings have been applied successfully in the development of new fuel cell systems for FCEVs, in particular the second-generation Toyota MIRAI.

Original languageEnglish
Article number044523
JournalJournal of the Electrochemical Society
Issue number4
Publication statusPublished - Apr 1 2022

All Science Journal Classification (ASJC) codes

  • Electronic, Optical and Magnetic Materials
  • Renewable Energy, Sustainability and the Environment
  • Surfaces, Coatings and Films
  • Electrochemistry
  • Materials Chemistry


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