Mechanical Performance Degradation of ECO EPDM Elastomers in Acidic Fuel Cell Environments

Sustainable ethylene propylene diene monomer (EPDM) elastomers are gaining traction as eco-friendly sealing materials in fuel cell applications. This study evaluates the mechanical degradation behavior of two ECO EPDM formulations-one reinforced with circular carbon black (CCB EPDM), and the other with recycled carbon black (RCB EPDM)-under conditions representative of acidic fuel cell environments. The samples underwent thermal aging at 90 °C for 1000 h, and were immersed in aqueous H₂SO₄ solutions of varying concentrations (1 M, 0.1 M, and 0.001 M) for 1000 h at the same temperature. Gravimetric and volumetric swelling measurements revealed that RCB EPDM experienced significantly higher mass and volume uptake, particularly at intermediate acid concentration, indicating greater susceptibility to fluid ingress. Mechanical testing, including measurement of tensile strength, Shore A hardness, and IRHD microhardness, showed that while RCB EPDM exhibited higher initial strength, it degraded more severely under thermal and acidic exposure. SEM-EDS analysis revealed microstructural damage and compositional changes, with RCB EPDM displaying more pronounced oxidation and surface erosion. In contrast, CCB EPDM demonstrated greater retention of mechanical integrity, greater dimensional stability, and lower variability across aging conditions. These findings highlight the advantages of circular carbon black in enhancing the durability of ECO EPDM compounds in acidic and thermally dynamic fuel cell environments.