Hydrogen is at the forefront of clean energy use and storage in the goal to drastically reduce anthropogenic carbon dioxide and combat global climate change. However, hydrogen production to-date is accomplished via steam methane reforming which, for every ton of hydrogen produced 5.5 tons of CO₂ is liberated. One viable technical solution for production of clean hydrogen is water electrolysis. To this end DOE has implemented the Hydrogen Earthshot initiative to cleanly produce hydrogen at 2 $/kg by 2025 and 1 $/kg by 2030.

Of the several commercial water electrolysis technologies available, proton exchange membrane water electrolysis (PEMWE) currently offers the most benefits including operations at low temperature, differential pressure, and high current density (≥3 A/cm²). Commercialization of PEMWE has advanced rapidly despite several significant disadvantages which include the necessity of scarce expensive platinum-group metal (PGM) catalysts, expensive perfluorinated membranes, and significant environmental impacts of perfluorinated alkyl substances (PFAS) used in membrane production. The solution to these challenges is the development of alkaline exchange membrane water electrolysis (AEMWE) which retains the advantageous characteristics of PEMWE without the need for PGM catalysts or perfluorinated membranes.

Here in, we report on our current progress of AEMWEs, which covers PGM-free catalyst development, low-cost and durable AEM development and electrode design development. From a commercial point of view, given a high-performance durable membrane, manufacturing MEAs is a critical next step toward commercialization. Therefore, development of an AEM with accessible thermal transitions prior to the onset of quaternary ammonium degradation is key to enabling proven MEA fabrication techniques such as hot-pressing and decal transfer of electrodes. Through a novel synthetic approach, we will describe the preparation of functionalized copolymers and terpolymers containing latent cross-linking functionality. Ultimately, we will demonstrate the manufacturability of MEAs from our PGM-free catalysts and membrane materials employing hot-pressing and decal transfer of electrodes along with single cell evaluations. We will also discuss factors that affect the degradation of AEMWEs and solutions to address these challenges.