Fast delamination of fuel cell Catalyst-Coated membranes using High-Intensity ultrasonication

This study demonstrates a rapid and facile method for separating the central membrane and catalyst-coated material from production scrap fuel cell catalyst-coated membranes (CCMs), facilitating a circular economy of technologically critical metals. A novel approach is presented using high-intensity ultrasonication with two distinct sonotrode configurations for rapid delamination at ambient temperature in water. This technique utilises cavitation, where high-frequency sound waves create, expand, and collapse microbubbles, generating high-speed jets, shockwaves, and acoustic streaming. This process effectively separates the membrane and catalyst while maintaining their overall integrity of the former. A cylindrical sonotrode (20 mm diameter) was used to optimise process parameters for smaller CCM samples to minimise time and energy consumption.