Characterisation of mechanical behaviour and coupled electrical properties of polymer electrolyte membrane fuel cell gas diffusion layers

Local compression distribution in the gas diffusion layer (GDL) of a polymer electrolyte membrane fuel cell (PEMFC) and the associated effect on electrical material resistance are examined. For this purpose a macroscopic structural material model is developed based on the assumption of orthotropic mechanical material behaviour for the fibrous paper and non-woven GDLs. The required structural material parameters are measured using depicted measurement methods. The influence of GDL compression on electrical properties and contact effects is also determined using specially developed testing tools. All material properties are used for a coupled 2D finite element simulation approach, capturing structural as well as electrical simulation in combination. The ohmic voltage losses are evaluated assuming constant current density at the catalyst layer and results are compared to cell polarisation measurements for different materials.     

Inhomogeneous compression of PEMFC gas diffusion layer: Part II. Modeling the effect

The effect of inhomogeneous compression of GDL on the mass and charge transfer in PEMFC is studied. The model utilizes experimentally evaluated GDL parameters as a function of thickness. The modeling results are compared with a conventional model that excludes the effects. As a result, it is shown that the inhomogeneous compression has a significant effect on the current density distribution because of the varying contact resistance between GDL and electrode. This also implies that there are possible hot spots occurring inside the electrode, and thus inhomogeneous compression can have significant effects on the lifetime and local performance of the cell. According to the achieved results, the inhomogeneous compression of GDL cannot be neglected.     

Numerical study on the compression effect of gas diffusion layer on PEMFC performance

A numerical method is developed to study the effect of the compression deformation of the gas diffusion layer (GDL) on the performance of the proton exchange membrane fuel cell (PEMFC). The GDL compression deformation, caused by the clamping force, plays an important role in controlling the performance of PEMFC since the compression deformation affects the contact resistance, the GDL porosity distribution, and the cross-section area of the gas channel. In the present paper, finite element method (FEM) is used to first analyze the ohmic contact resistance between the bipolar plate and the GDL, the GDL deformation, and the GDL porosity distribution. Then, finite volume method is used to analyze the transport of the reactants and products. We investigate the effects of the GDL compression deformation, the ohmic contact resistivity, the air relative humidity, and the thickness of the catalyst layer (CL) on the performance of the PEMFC. The numerical results show that the fuel cell performance decreases with increasing compression deformation if the contact resistance is negligible, but an optimal compression deformation exists if the contact resistance is considerable.     

Analysis of surface and interior degradation of gas diffusion layer with accelerated stress tests for polymer electrolyte membrane fuel cell

The effects of surface and interior degradation of the gas diffusion layer (GDL) on the performance and durability of polymer electrolyte membrane fuel cells (PEMFCs) have been investigated using three freeze-thaw accelerated stress tests (ASTs). Three ASTs (ex-situ, in-situ, and new methods) are designed from freezing ?30 °C to thawing 80 °C by immersing, supplying, and bubbling, respectively. The ex-situ method is designed for surface degradation of the GDL. Change of surface morphology from hydrophobic to hydrophilic by surface degradation of GDL causes low capillary pressure which decreased PEMFC performance. The in-situ method is designed for the interior degradation of the GDL. A decrease in the ratio of the porosity to tortuosity by interior degradation of the GDL deteriorates PEMFC performance. Moreover, the new method showed combined effects for both surface and interior degradation of the GDL. It was identified that the main factor that deteriorated the fuel cell performance was the increase in mass transport resistance by interior degradation of GDL. In conclusion, this study aims to investigate the causes of degraded GDL on the PEMFC performance into the surface and interior degradation and provide the design guideline of high-durability GDL for the PEMFC.     

Numerical modeling and experimental study of the influence of GDL properties on performance in a PEMFC

This work is to study the effect of properties of gas diffusion layer (GDL) on performance in a polymer electrolyte membrane fuel cell (PEMFC) by both numerical simulation and experiments. The 1-dimension numerical simulation using the mixture-phase model is developed to calculate polarization curve. We are able to estimate optimum GDL properties for cell performance from numerical simulation results. Various GDLs which have different properties are prepared to verify accuracy of the simulation results. The contact angle and gas permeability of GDLs are controlled by polytetrafluoroethylene (PTFE) content in micro-porous layers (MPLs). MPL slurry is prepared by homogeneous blending of carbon powder, PTFE suspension, isopropyl alcohol and glycerol. Then the slurry is coated on gas diffusion mediums (GDMs) surface with controlled thickness by blade coating method. Non-woven carbon papers which have different thicknesses of 200 μm and 380 μm are used as GDMs. The prepared GDLs are measured by surface morphology, contact angle, gas permeability and through-plane electrical resistance. Moreover, the GDLs are tested in a 25 cm² single cell at 70 °C in humidified H₂/air condition. The contact angle of GDL increases with increasing PTFE content in MPL. However, the gas permeability and through-plane electrical conductivity decrease with increasing PTFE content and thickness of GDM. These changes in properties of GDL greatly influence the cell performance. As a result, the best performance is obtained by GDL consists of 200 μm thick non-woven carbon paper as GDM and MPL contained 20 wt.% PTFE content.     

Gas diffusion layer for proton exchange membrane fuel cells—A review

Gas diffusion layer (GDL) is one of the critical components acting both as the functional as well as the support structure for membrane-electrode assembly in the proton exchange membrane fuel cell (PEMFC). The role of the GDL is very significant in the H₂/air PEM fuel cell to make it commercially viable. A bibliometric analysis of the publications on the GDLs since 1992 shows a total of 400+ publications (>140 papers in the Journal of Power Sources alone) and reveals an exponential growth due to reasons that PEMFC promises a lot of potential as the future energy source for varied applications and hence its vital component GDL requires due innovative analysis and research. This paper is an attempt to pool together the published work on the GDLs and also to review the essential properties of the GDLs, the method of achieving each one of them, their characterization and the current status and future directions. The optimization of the functional properties of the GDLs is possible only by understanding the role of its key parameters such as structure, porosity, hydrophobicity, hydrophilicity, gas permeability, transport properties, water management and the surface morphology. This paper discusses them in detail to provide an insight into the structural parts that make the GDLs and also the processes that occur in the GDLs under service conditions and the characteristic properties. The required balance in the properties of the GDLs to facilitate the counter current flow of the gas and water is highlighted through its characteristics.     

Three-dimensional modeling of a PEMFC with serpentine flow field incorporating the impacts of electrode inhomogeneous compression deformation

The effects of compression deformation of gas diffusion layer (GDL) on the performance of a proton exchange membrane fuel cell (PEMFC) with serpentine flow field were numerically investigated by coupling two-dimensional GDL mechanical deformation model based on Finite Element Analysis and three-dimensional two-phase PEMFC model with incorporating the deformation impacts. Emphasis is located on exploring the influences of assembly pressure on the non-uniform geometric deformation and distributions of transport properties in the GDL, flow behaviors and local distributions of oxygen and current density, cell polarization curves and net power densities of the PEMFC. It was indicated that the non-uniform deformation of GDL results in inhomogeneous distributions of porosity and permeability in the GDL due to the presence of rib-channel pattern, and the transport properties in the under-rib region are greatly reduced with increasing the assembly pressure, consequently weakening the gas flow and oxygen transport in the under-rib region and increasing the non-uniformity of local current density distribution. As for the overall cell performance, however, attributed to the tradeoff between the adverse impacts of GDL compression on mass transport loss and positive effects on reducing ohmic loss, the overall cell performance is firstly increased and then decreased with increasing assembly pressure from 0 MPa to 5.0 MPa, and the maximum cell performance can be achieved at the assembly pressure of about 1.0 MPa for all cases studied. As compared with the case for zero assembly pressure, the maximum net power density of the cell can be improved by about 7.7%, 9.9%, 10.5% and 10.7% for the cathode stoichiometry ratios of 2.0, 3.0, 4.0 and 5.0@i_ref = 1 A·cm⁻², respectively. Practically, it is suggested that the assembly pressure is controlled in an appropriate range of 0.5 MPa–1.5 MPa such that the cell net power can be boosted and pressure head requirement for the pump can be maintained in a appropriate level.     

Optimum design of the slotted-interdigitated channels flow field for proton exchange membrane fuel cells with consideration of the gas diffusion layer intrusion

The design of the flow field greatly affects the flow distribution and the final performance of the proton exchange membrane fuel cell (PEMFC) system. The clamping force between the gas diffusion layer (GDL) and the flow field plate (FFP) will cause the inhomogeneous compression of the GDL. Then the GDL will be intruded into the reactant gas channels and eventually change the flow distribution. This paper presents a study on the effect of the intrusion of the GDL on the flow field in a PEMFC, and tries to explain the reason for poor performance of the previous design of the flow field other than those have been studied in other papers such as GDL roughness, porosity, etc. First of all, a linear analytical model is used to analyze the sensitivities of the flow field to the GDL intrusion, and then used to estimate the effect of the GDL intrusion on the flow field distribution. Secondly, a multi-objective optimization model is proposed to eliminate the nonuniform distribution in the flow field with the GDL intrusion taken into consideration. Subsequently, three different designs are analyzed and compared with each other as a demonstration to show the effect of the GDL intrusion. From the analysis results, it is recommended that the effect of the GDL intrusion on the multi-depth flow field should be taken into consideration and the flow field should be insensitive to the GDL intrusion to obtain high robust performance. The results obtained in the study provide the designer some useful guidelines in the concept design of flow field configurations.     

Effect of electrochemical aging on the interaction between gas diffusion layers and the flow field in a proton exchange membrane fuel cell

Gas diffusion layer (GDL) is a porous medium placed between the flow field and the catalyst layer in a proton exchange membrane fuel cell (PEMFC), and experiences electrochemical aging and mechanical stresses during usage. In the present work carbon cloth and carbon paper, two commonly used GDLs in PEMFC, are electrochemically aged in a simulated PEMFC environment. The results indicate that carbon paper is less prone to oxidation when compared to carbon cloth, which can be attributed to higher degree of graphitization of carbon fibers in the paper. However, carbon paper suffers greater loss of structural stability due to the adverse effects of aging on the fiber matrix interface. Increased weakening of paper when compared to cloth, after electrochemical aging, results in higher residual strain when subjected to cyclic compression and an increased intrusion of paper into the flow field channel when compared to cloth GDL.     

Uneven gas diffusion layer intrusion in gas channel arrays of proton exchange membrane fuel cell and its effects on flow distribution

Intrusion of the gas diffusion layer (GDL) into gas channels due to fuel cell compression has a major impact on the gas flow distribution, fuel cell performance and durability. In this work, the effect of compression resulting in GDL intrusion in individual parallel PEMFC channels is investigated. The intrusion is determined using two methods: an optical measurement in both the in-plane and through-plane directions of GDL, as well as an analytical fluid flow model based on individual channel flow rate measurements. The intrusion measurements and estimates obtained from these methods agree well with each other. An uneven distribution of GDL intrusion into individual parallel channels is observed. A non-uniform compression force distribution derived from the clamping bolts causes a higher intrusion in the end channels. The heterogeneous GDL structure and physical properties may also contribute to the uneven GDL intrusion. As a result of uneven intrusion distribution, severe flow maldistribution and increased pressure drop have been observed. The intrusion data can be further used to determine the mechanical properties of GDL materials. Using the finite element analysis software program ANSYS, the Young's modulus of the GDL from these measurements is estimated to be 30.9 MPa.     

Gas diffusion layers for PEM fuel cells: Materials,properties and manufacturing – A review

The complexity in proton exchange membrane fuel cell (PEMFC) stack stems from the fact that numerous physio-chemical processes as well as multi-functional components are involved in its operation. Among the various components a Gas Diffusion Layer (GDL) being an integral component that plays a significant role in determining the performance, durability, and the dynamic characteristics, when air is used as oxidant. In addition, it serves as an armour to safeguard the membrane (Nafion), which is a delicate as well as one of the most expensive components of the PEMFC stack. A comprehensive insight on the GDL can help us to assess the fuel cell stack performance and durability. Apparently, the gas (hydrogen and air/oxygen) being converted to the energy in a PEM fuel cell needs to be diffused uniformly for which surface attributes and porosity must also be well interpreted. This review is a comprehensive assessment made on the fundamental mechanism of the diffusion process along with the various materials involved and evaluating their pros and cons. Eventually, the various manufacturing techniques involved in the GDL fabrication process are also reviewed holistically. It is envisaged that the additive manufacturing process can be a potential option to fabricate a GDL in a cost-effective and simple manufacturing approach.     

Microstructure reconstruction and characterization of PEMFC electrodes

We reconstruct a proton exchange membrane fuel cell (PEMFC) catalyst layer (CL) and a non-woven carbon paper gas diffusion layer (GDL) by specially-designed stochastic methods. The reconstructed microstructures evidently distinguish all the participating components in the composite GDL/CL. Characterization analyses with respect to the reconstructed GDL/CL give important structural properties such as geometrical connectivity of an individual phase, pore size distribution, and volume-specific interfacial area. Self-developed Lattice Boltzmann (LB) models are established to calculate effective transport physical properties including effective thermal/electric conductivity and effective species diffusivity of the reconstructed GDL/CL, and permeability of the reconstructed GDL. Accordingly, we obtain tortuosity values for pore or solid phase in the reconstructed GDL/CL.     

Evaluating breakthrough pressure in gas diffusion layers of proton exchange membrane fuel cells

This paper studied the breakthrough pressure for liquid water to penetrate the gas diffusion layer （GDL） of a pro- ton exchange membrane fuel cell （PEMFC）. An ex-situ testing was conducted on a transparent test cell to visu- alize the water droplet formation and detachment on the surface of different types of GDLs through a CCD cam- era. The breakthrough pressure, at which the liquid water penetrates the GDL and starts to form a droplet, was measured. The breakthrough pressure was found to be different for the GDLs with different porosities and thick- nesses. The equilibrium pressure, which is defined as the minimum pressure required maintaining a constant flow through the GDL, was also recorded. The equilibrium pressure was found to be much lower than the breakthrough pressure for the same type of GDL. A pore network model was modified to further study the relationship between the breakthrough pressure and the GDL properties and thicknesses. The breakthrough pressure increases for the thick GDL with smaller micro-pore size.     

Effects of gas-diffusion layer properties on the performance of the cathode for high-temperature polymer electrolyte membrane fuel cell

The role of the gas-diffusion layer (GDL) in high-temperature polymer electrolyte fuel cell (HT-PEMFC) differs from that in low-temperature PEMFC GDL due to operating conditions and environment. Determining the GDL's structural parameters that affect its transport properties, and how these properties impact HT-PEMFC performance was urgently required. Four commercial GDLs were employed in HT-PEMFC cathode's GDE and was examined using X-μCT, mercury intrusion porosimetry, and an optical microscope to analyze structural parameters and characteristics. Fractal theory was applied to comprehend the gas transmission property of GDL, and the validity of the theory was confirmed through ex-situ through-plane gas permeability measurement. The analysis indicated that the porosity of GDL influenced by the crack region of the MPL has more impact on the GDL's gas transmission than its thickness. After that, we established a correlation between HT-PEMFC cathode performance and GDL porosity and theoretical gas transmission properties using R² coefficient of determination.     

Performance loss of proton exchange membrane fuel cell due to hydrophobicity loss in gas diffusion layer: Analysis by multiscale approach combining pore network and performance modelling

Loss of hydrophobicity in the gas diffusion layers (GDL) is sometimes suggested as a potential mechanism to explain in part the performance loss of PEMFC. The present study proposes a numerical methodology to analyse this effect by combining pore network modelling (PNM) and performance modelling (PM): the PNM/PM approach. PNM allows simulating the decrease of through-plane gas diffusion coefficient in the GDL as a function of the hydrophobicity loss, which is taken into account through the increase in the fraction of hydrophilic pores in GDL. Then PM based on Darcy equations allows simulating performance loss of PEMFC as a function of gas diffusion decay. This coupling shows that the loss of hydrophobic treatment increases flooding, decreases performance, and increases current density heterogeneities between inlet and outlet of the cell. Interestingly, this degradation is found to be highly non-linear, mainly because of the non-linear influence of the fraction of hydrophilic pores on gas diffusion (this is due to the existence of a percolation threshold associated with the hydrophilic pore sub-network) as well as the non-linear behaviour of electrochemistry with gas diffusion. This study also shows that the loss of hydrophobicity in a GDL is a very suitable candidate to explain performance loss rates that are classically observed during long-term tests. The proposed methodology may also help linking other local properties of components to fuel cell global performance.     

Examining the effect of the secondary flow-field on polymer electrolyte fuel cells using X-ray computed radiography and computational modelling

Flow-fields are key factors in determining the operation of fuel cells. While extensive work has been conducted to develop and optimise the reactant flow and current collection performance of polymer electrolyte membrane fuel cell (PEMFC) components, there is a factor that remains largely unaccounted for. Depending on how a membrane electrode assembly (MEA) is incorporated into a cell, there will often be a small gap between the edge of the gas diffusion layer (GDL) and the seal or bipolar plate. This gap acts as a ‘secondary flow-field’ (SFF) that can bypass or affect/augment the conventional or ‘primary flow-field’. Understanding how this affects performance (either positively or adversely) is essential for holistic flow-field design. This paper describes the issues associated with the SFF, examines how cell compression affects its width due to lateral expansion of the GDL and discusses the results of a 3-D computational model that investigates the effect of the SFF during dead-ended anode (DEA) operation for a fuel cell without a macroscopic (conventional) anode flow-field.     

Numerical study for in-plane gradient effects of cathode gas diffusion layer on PEMFC under low humidity condition

A numerical study about in-plane porosity and contact angle gradient effects of cathode gas diffusion layer (GDL) on polymer electrolyte membrane fuel cell (PEMFC) under low humidity condition below 50% relative humidity is performed in this work. Firstly, a numerical model for a fuel cell is developed, which considers mass transfer, electrochemical reaction, and water saturation in cathode GDL. For water saturation in cathode GDL, porosity and contact angle of GDL are also considered in developing the model. Secondly, current density distribution in PEMFC with uniform cathode GDL is scrutinized to design the gradient cathode GDL. Finally, current density distributions in PEMFC with gradient cathode GDL and uniform cathode GDL are compared. At the gas inlet side, the current density is higher in GDL with a gradient than GDL with high porosity and large contact angle. At the outlet side, the current density is higher in GDL with a gradient than GDL with low porosity and small contact angle. As a result, gradient cathode GDL increases the maximum power by 9% than GDL with low porosity and small contact angle. Moreover, gradient cathode GDL uniformizes the current density distribution by 4% than GDL with high porosity and large contact angle.     

Compress effects on porosity,gas‐phase tortuosity,and gas permeability in a simulated PEM gas diffusion layer

Among the parameters to take into account in the design of a proton exchange membrane fuel cell (PEMFC), the energy conversion efficiency and material cost are very important. Understanding in deep the behavior and properties of functional layers at the microscale is helpful for improving the performance of the system and find alternative materials. The functional layers of the PEMFC, i.e., the gas diffusion layer (GDL) and catalyst layer, are typically porous materials. This characteristic allows the transport of fluids and charges, which is needed for the energy conversion process. Specifically, in the GDL, structural parameters such as porosity, tortuosity, and permeability should be optimized and predicted under certain conditions. These parameters have effects on the performance of PEMFCs, and they can be modified when the assembly compression is effected. In this paper, the porosity, gas‐phase tortuosity, and through‐plane permeability are calculated. These variables change when the digitally created GDL is under compression conditions. The compression effects on the variables are studied until the thickness is 66% of the initial value. Because of the feasibility to handle problems in the porous media, the fluid flow behavior is evaluated using the lattice Boltzmann method. Our results show that when the GDL is compressed, the porosity and through‐plane permeability decrease, while the gas‐phase tortuosity increases, i.e., increase the gas‐phase transport resistance. Copyright © 2015 John Wiley & Sons, Ltd.     

Effects of needle orientation and gas velocity on water transport and removal in a modified PEMFC gas flow channel having a hydrophilic needle

Water management is critical to the performance and operation of the proton exchange membrane fuel cell (PEMFC). Effective water removal from the gas diffusion layer (GDL) surface exposed to the gas flow channel in PEMFC mitigates the water flooding of and improves the reactants transport into the GDL, hence benefiting the PEMFC performance. In this study, a 3D numerical investigation of water removal from the GDL surface in a modified PEMFC gas flow channel having a hydrophilic needle is carried out. The effects of the needle orientation (inclination angle) and gas velocity on the water transport and removal are investigated. The results show that the water is removed from the GDL surface in the channel for a large range of the needle inclination angle and gas velocity. The water is removed more effectively, and the pressure drop for the flow in the channel is smaller for a smaller needle inclination angle. It is also found that the modified channel is more effective and viable for water removal in fuel cells operated at smaller gas velocity.     

Development of a novel hydrophobic/hydrophilic double micro porous layer for use in a cathode gas diffusion layer in PEMFC

In this study, a gas diffusion layer (GDL) was modified to improve the water management ability of a proton exchange membrane fuel cell (PEMFC). We developed a novel hydrophobic/hydrophilic double micro porous layer (MPL) that was coated on a gas diffusion backing layer (GDBL). The water management properties, vapor and water permeability, of the GDL were measured and the performance of single cells was evaluated under two different humidification conditions, R.H. 100% and 50%. The modified GDL, which contained a hydrophilic MPL in the middle of the GDL and a hydrophobic MPL on the surface, performed better than the conventional GDL, which contained only a single hydrophobic MPL, regardless of humidity, where the performance of the single cell was significantly improved under the low humidification condition. The hydrophilic MPL, which was in the middle of the modified GDL, was shown to act as an internal humidifier due to its water absorption ability as assessed by measuring the vapor and water permeability of this layer.