A novel material fabrication method for the PEM fuel cell bipolar plate

Gelcasting, a near net-shape forming process, is suitable for manufacturing of structural ceramics with various shapes. In this study, the gelcasting process was adopted to obtain the material for PEM fuel cell bipolar plates. The mesocarbon microbead (MCMB) that has the unique self-sintering property was chosen as the starting material. In order to optimize the MCMB suspensions for gelcasting, the zeta potentials of the MCMB particles dispersing in water were investigated. A stable MCMB suspension with solid loading up to 66.7 wt.% was prepared from which the uniform green parts with complex structures were successfully molded. Finally, the physical properties of green parts and sintered samples were evaluated.     

New electroplated aluminum bipolar plate for PEM fuel cell

Further improvement in the performance of the polymer electrolyte membrane fuel cells as a power source for automotive applications may be achieved by the use of a new material in the manufacture of the bipolar plate. Several nickel alloys were applied on the aluminum substrate, the use of aluminum as a bipolar plate instead of graphite is to reduce the bipolar plate cost and weight and the ease of machining. The electroplated nickel alloys on aluminum substrate produced a new metallic bipolar plate for PEM fuel cell with a higher efficiency and longer lifetime than the graphite bipolar plate due to its higher electrical conductivity and its lower corrosion rate. Different pretreatment methods were tested; the optimum method for pretreatment consists of dipping the specimen in a 12.5% NaOH for 3 min followed by electroless zinc plating for 2 min, then the specimen is dipped quickly in the electroplating bath after rinsing with distilled water. The produced electroplate was tested with different measurement techniques, chosen based on the requirement for a PEM fuel cell bipolar plate, including X-ray diffraction, EDAX, SEM, corrosion resistance, thickness measurement, microhardness, and electrical conductivity.     

NUMERICAL analysis of the effects of current collector plate geometry on performance in a cylindrical PEM fuel cell

In this study, a numerical analysis was conducted to investigate the effects of current collector plate geometry on performance in a cylindrical PEM (Proton Exchange Membrane) fuel cell. For this purpose, 2 anode and cathode current collector plate geometries for each helix channel and straight channel were designed. Current collector plates with different geometries were combined with different sequences, and four different main model fuel cell geometries were created. Accordingly, anode and cathode current collector plates for Model-1, Model-2, Model-3, and Model-4 geometries were determined as straight-straight, helix-helix, straight-helix, and helix-straight, respectively. Using these model geometries, simulations were conducted for three different operating pressures, four different operating flow rates, and ten different operating voltages. It was observed that when helix flow channels were used instead of straight flow channels in current collection plate geometries, the flow density increased by approximately 63.18%. The results also revealed that the current density increased by approximately 206.9% when the fuel cell operating pressure increased. In addition, the power density increased as the operating pressure increased. As the gas flow to anode and cathode increased, a 19.05% increase in the current increase in the pressure difference was observed. As a result, the helix flow channel usage performed better than the straight flow channel for the parameters adopted in this study.     

A comprehensive review on PEM water electrolysis

Hydrogen is often considered the best means by which to store energy coming from renewable and intermittent power sources. With the growing capacity of localized renewable energy sources surpassing the gigawatt range, a storage system of equal magnitude is required. PEM electrolysis provides a sustainable solution for the production of hydrogen, and is well suited to couple with energy sources such as wind and solar. However, due to low demand in electrolytic hydrogen in the last century, little research has been done on PEM electrolysis with many challenges still unexplored. The ever increasing desire for green energy has rekindled the interest on PEM electrolysis, thus the compilation and recovery of past research and developments is important and necessary. In this review, PEM water electrolysis is comprehensively highlighted and discussed. The challenges new and old related to electrocatalysts, solid electrolyte, current collectors, separator plates and modeling efforts will also be addressed. The main message is to clearly set the state-of-the-art for the PEM electrolysis technology, be insightful of the research that is already done and the challenges that still exist. This information will provide several future research directions and a road map in order to aid scientists in establishing PEM electrolysis as a commercially viable hydrogen production solution.     

Preparation and properties on the graphite/polypropylene composite bipolar plates with a 304 stainless steel by compression molding for PEM fuel cell

Graphite/polymer composites have high corrosion resistance, low contact resistance and low fabrication cost but low cell efficiency and mechanical strength. This study examined the electrical and mechanical properties of graphite/polypropylene composite bipolar plates. Carbon nanotubes (CNTs) were used to improve the electrical properties of the graphite/PP composites. Although the electrical properties increased when excess conducting filler was added to the composite, the mechanical strength decreased significantly. 304 stainless steel (304 SS) plates with different thicknesses were used as the support material of a graphite/PP composite bipolar plate. The 304 SS-supported graphite/PP composite bipolar plate had an optimum CNTs/graphite/PP composite composition of 1.2, 83 and 17 wt.%, respectively. The flexural strength of the 304 SS-supported graphite/PP composites increased from 35 to 58 MPa with increasing 304 SS thickness from 0.5 to 1 mm. The power density of the graphite bipolar plate and 304 SS-supported graphite/PP composite bipolar plate were 968 and 877 mW cm⁻², respectively. The 304 SS complemented the mechanical strength of the graphite/PP composite bipolar plate as well as the cell efficiency.     

Numerical investigation of PEM electrolysis cell with the new interdigitated-jet hole flow field

The flow field structure has important influences on the mass and heat transfer and the distribution uniformity in the proton exchange membrane electrolysis cell (PEMEC). In this paper, the application and operation modes and the structural parameters of the new interdigitated-jet hole flow field (JHFF) are explored, to guide the processing of the JHFF and provide references for experimental testing. A three-dimensional and two-phase model is established to simulate the effect of JHFF on the performance of PEMEC. The results demonstrate that compared with the application of JHFF only on the anode side, the application of JHFF on both sides of the anode and cathode can increase the temperature distribution uniformity and polarization performance by 41.78% and 16.25%, respectively. By increasing the number of inlet flow channels and using the counter-flow water supply mode, the temperature distribution can be more uniform. The lower the height of jet holes, the better the normal mass transfer and polarization performance, while the worse the temperature distribution uniformity. Reducing the diameter of the inlet jet holes can improve the normal mass transfer performance in the porous electrode. Synthetically, the hole height of 0.2 mm and the hole diameter of 0.4 mm are recommended. The findings provide theoretical guidance for the practical application of JHFF in PEMEC so that the positive role of JHFF in improving electrolysis performance can be fully realized.     

Simulation and experimental analysis of the clamping pressure distribution in a PEM fuel cell stack

High performance and efficiency are often reported in single-cell polymer electrolyte membrane (PEM) fuel cell (FC) experiments. This however, can reduce substantially when moving from single-cell experiments to multiple cells. Fuel cell performance is degraded for many reasons when adding cells, but; possibly the most important, is contact resistance between the bipolar plate and gas diffusion layer (GDL). Contact resistance is in direct relation to the clamping configuration and clamping pressure applied to a FC stack. Simulation of a single cell and 16-cell FC was performed at various clamping pressures resulting in detailed 3D plots of stress and deformation. The stress on the GDL, for any value of clamping pressure simulated in this study, is around 1.5 MPa for the 16-cell stack and around 4 MPa in single cell simulations. Experimental testing of clamping pressure effects was performed on a 16-cell stack by placing a thin pressure-sensitive film between GDL and bipolar plate. Clamping pressure was applied using various loads, durations, and two types of GDLs. The results from experimental testing show that pressure on the GDL is in the range of 0–2.5 MPa. When using rectangular cells, experimental results show nearly zero pressure in the center of each cell and the center cells of the stack, regardless of clamping method.     

Annealing induced interfacial layers in niobium-clad stainless steel developed as a bipolar plate material for polymer electrolyte membrane fuel cell stacks

Roll-bonded niobium (Nb)-clad 304 L stainless steel (SS) is currently being developed as a metallic bipolar plate material for polymer electrolyte membrane fuel cell stacks. Prior work has shown that post-roll annealing significantly softens the constituent core and cladding materials, enhancing the ductility and formability of each. However under the vacuum annealing condition employed in the previous study (900 s, 982 °C (1800 F)), an interfacial layer was observed to form between the two bonded materials. Subsequent bending and flattening tests indicated brittle failure of this interfacial region under high strain conditions. The present study employs transmission electron microscopy to examine the composition, structure, and thickness of phases generated at the Nb/SS interface as functions of annealing temperature and time. Corresponding selected electron diffraction patterns indicate that above a threshold annealing temperature of ∼950 °C, the formation of (Fe_1−xCr_x)₂Nb appears to control the failure behavior of the Nb/304 L SS material. Annealing treatments conducted below this temperature generally avoid the formation of this intermetallic layer.     

Novel hybrid coating of TiN and carbon with improved corrosion resistance for bipolar plates of PEM water electrolysis

Surface modification of Ti based bipolar plates (BPs) could be an effective solution to prevent the formation of low-conductive oxide film, promote the corrosion resistance and electronic conductivity as well. In this work, a novel hybrid coating composed of nano-sized TiN and carbonaceous phases (TiN–C) was successfully established on a Ti substrate via a combined electrophoretic deposition and thermal treatment process. Various physiochemical characterizations revealed that the coating was uniform, and the formation of the nano-sized TiN and carbonaceous composites reduced the interfacial contact resistance significantly. The potentiodynamic and potentiostatic polarization tests indicated that the hybrid coating TiN–C prepared at 400 °C had a corrosion current density of only 1.41 μA cm⁻², which was an order of magnitude lower than that (36.02 μA cm⁻²) of the bare Ti. Furthermore, the as-prepared coating showed excellent durability in both the simulated PEMWE environment and the PEMWE cell under polarization at 1.7 V for more than 300 h.     

The electrical and corrosion properties of carbon nanotube coated 304 stainless steel/polymer composite as PEM fuel cell bipolar plates

In this study, the contact resistance and corrosion resistance of three different types of plates used as PEM fuel cell bipolar plates are investigated, viz. (1) 304 stainless steel without carbon nanotube treatment that was then sandwiched between polymer composites, (2) CNT particles placed on the surface of the 304 stainless steel that was then sandwiched between polymer composites, and (3) direct CNTs coated 304 stainless steel that was then sandwiched between polymer composites. Both treated and untreated 304 stainless steel covered with the polymer composites exhibited good corrosion resistance. The results showed that the highest improvement of the contact resistance was accomplished by the direct deposition of CNTs on the 304 stainless steel insert. The results of the potentiodynamic and potentiostatic measurements also showed that direct CNTs deposition on the 304 stainless steel insert did not degrade the corrosion performance under PEM fuel cell operating conditions.     

Efficient hydrogen production from aqueous methanol in a PEM electrolyzer with porous metal flow field: Influence of PTFE treatment of the anode gas diffusion layer

In a proton exchange membrane (PEM) methanol electrolyzer, the even supply of reactant to and the smooth removal of carbon dioxide from the anode are very important in order to achieve a high hydrogen production performance. An appropriate design of flow field and gas diffusion layer (GDL) is a key factor in satisfying the above requirements. Previous research has shown that hydrogen production performance of the PEM methanol electrolyzer cell was largely improved with a porous flow field made of sintered spherical metal powder compared with a conventional groove type flow field. Based on this improvement, the current study investigated the influence of polytetrafluoroethylene (PTFE) treatment of the anode GDL on hydrogen production performance of the PEM methanol electrolyzer with porous metal flow fields. Influences of operating conditions such as methanol concentration and cell temperature with the flow field were also investigated.     

An electrochemical study of a PEM stack for water electrolysis

The electrochemical properties of a proton exchange membrane (PEM) stack electrolyzer (9 cells of 100 cm² geometrical area) were investigated at different temperatures. An amount of H₂ of ∼270 l h⁻¹ was produced at 60 A (600 mA cm⁻²) and 70 °C under 876 W of applied electrical power. The corresponding specific energy consumed in the process was 3.24 Wh·l⁻¹H₂. The Faradic and electrical efficiencies were determined. Overall stack efficiencies of 73% and 85%, at 60 A and 70 °C, with respect to the low and high heating value of hydrogen, respectively, were obtained. These results confirmed the successful scale-up of a previous lab-scale device.     

High-density plasma nitriding of AISI 316L for bipolar plate in proton exchange membrane fuel cell

Austenitic stainless steel (AISI 316L) is nitrided by inductively coupled plasma using a gas mixture of N₂ and H₂ at temperatures between 530 K and 650 K, and the corrosion resistance as well as the interfacial contact resistance (ICR) are measured in a simulated proton exchange membrane fuel cell (PEMFC) environment.After plasma nitriding, a nitrogen-expanded austenite layer, the so-called S-phase is formed in all nitrided samples. The ICR value of the nitrided samples decreases to approximately 10 mΩcm² after plasma nitriding. The sample nitrided at 590 K shows the best corrosion property, while the corrosion resistance of the sample nitrided at higher temperatures decreases because of the formation of Cr-depleted regions in the nitrided sample. By using high-density plasma, the process temperature can be reduced to such a low temperature that Cr depletion is not significant, but a dense S-phase is formed.     

Thermal and electrochemical durability of carbonaceous composites used as a bipolar plate of proton exchange membrane fuel cell

Thermal and electrochemical durability of carbonaceous composite plates, which are made from graphite powders and a resin for use as bipolar plates of PEMFC (proton exchange membrane fuel cell), were investigated. The thermal durability was investigated by TG (thermal gravimetry) coupled with DTA (differential thermal analysis) technique under air up to 600 °C. A weight loss was significant over 300 °C, but the hydrophobicity was decreased after heated at 80 °C for 192 h.The electrochemical durability was investigated in 10 μmol dm⁻³ of hydrochloric acid solution under nitrogen or oxygen atmosphere by means of potential holding test from 0.8 to 1.5 V against RHE (reversible hydrogen electrode) at 80 °C. During the potential holding tests, CO₂ production due to the corrosion was quantified by a GC (gas-chromatography) and the production was detectable above 1.3 V irrespective with atmosphere; on the other hand, it was clarified from the contact angle measurements that the hydrophobicity was changed below 1.3 V. The results of this study showed that the carbonaceous composite plates were electrochemically degraded under PEMFC condition and were seriously degraded in URFC (unitized regenerative fuel cell) condition.     

Proton exchange membrane water electrolysis system-membrane electrode assembly with additive

In proton exchange membrane water electrolysis system, the performance is highly affected by the anode materials and the operation modes. In addition, high voltages are for higher hydrogen production and also ozone for disinfection. After switching off of the power and restarted, a decrease in electric conductivity may lead to a performance drop in further hydrogen/ozone/generation. In this study, three different additives, A, Z and V are adopted which respectively mixed with the PbO₂ and to become anode catalyst ink. The characteristics of the anode catalysts are determined by interruptive power supply, electrochemical impedance spectroscopy, and cyclic voltammetry tests. The results show that additives A and Z have batter current efficiency than the other groups. Additionally, anode catalyst withadditive V possess the most outstanding durability among all groups.     

Factors affecting corrosion behavior of SS316L as bipolar plate material in PEMFC cathode environments

An empirical corrosion model for SS316L in simulated proton exchange membrane fuel cell (PEMFC) environments is developed based on systematic experimental data on the effects of various factors, such as acidity, fluoride ion concentration, temperature and polarization potential. Correlation parameters under different conditions are provided in tabulated forms and comparisons of the empirical model with experimental results are shown in graphical forms. The results show that the empirical model agrees very well with the experimental data except at the short initial polarization time and the model is applicable up to a polarization potential of 0.7 V. The results also show that polarization potential is the most sensitive parameter among all the parameters studied.     

Analysis of PEM fuel cell experimental data using principal component analysis and multi linear regression

Polarisation curves performed at the Fuel Cell System Laboratory (FC LAB) at Belfort on a PEM fuel cell stack using a homemade fully instrumented test bench led to more than 100 variables depending on time. Visualising and analysing all the different test variables are complex. In this work, we show how the Principal Component Analysis (PCA) method helps to explore correlations between variables and similarities between measurements at a specific sampling time (individuals). To complete this method, an empirical model of the PEM fuel cell is proposed by linking the different input parameters to the cell voltage using Multiple Linear Regression.     

Development of composite-metal hybrid bipolar plates for PEM fuel cells

In this study, in order to increase the electrical conductivity, a carbon composite-metal hybrid bipolar plate has been developed using pre-forming method followed by a plasma surface treatment. A pre-formed metal foil between the carbon fiber/polymer composite plates promotes the metal foil to follow the shape of the channels of the bipolar plates without tearing and permits a continuous flow of electrons. The pre-formed metal foil also reduces the residual stress between the composite and metal foils, which helps prevent delamination between the composite and metal foils. The composite surface has been treated with plasma to increase the contact area between the carbon fiber and the gas diffusion layer (GDL). The composite-metal hybrid bipolar plates have only 1.4% of the total electrical resistance of that of the conventional composite bipolar plates. Unit cell test results have proved that the developed composite-metal hybrid bipolar plates with reduced total electrical resistance increase the cell performance.     

Three-dimensional numerical analysis of PEM fuel cells with straight and wave-like gas flow fields channels

Using a three-dimensional computational model, numerical simulations are performed to investigate the performance characteristics of proton exchange membrane fuel cells (PEMFCs) incorporating either a conventional straight gas flow channel or a novel wave-like channel. The simulations focus particularly on the effect of the wave-like surface on the gas flow characteristics, the temperature distribution, the electrochemical reaction efficiency and the electrical performance of the PEMFCs at operating temperatures ranging from 323 K to 343 K. The numerical results reveal that the wave-like surface enhances the transport of the reactant gases through the porous layer, improves the convective heat transfer effect, increases the gas flow velocity, and yields a more uniform temperature distribution. As a result, the efficiency of the catalytic reaction is significantly improved. Consequently, compared to a conventional PEMFC, the PEMFC with a wave-like channel yields a notably higher output voltage and power density.     

Effect of primary parameters on the performance of PEM fuel cell

A one-dimensional, steady-state and isothermal model for a proton exchange membrane (PEM) fuel cell has been developed to investigate the effects of various parameters such as the molar fraction of nitrogen gas, relative humidity, temperature, pressure, membrane thickness, anode and cathode stoichiometric flow ratio and the distribution of oxygen in the cathode catalyst while water transfer in membrane is produced by diffusion, pressure gradient and electro-osmotic drag. The most critical problems to overcome in the proton exchange membrane (PEM) fuel cell technology are the water and thermal management. The results show that the cell performance increases as operating pressure and temperature are increased. The performance of cell can decrease by decreasing the relative humidity of inlet gases and increasing the membrane thickness. Increasing the anode and cathode stoichiometric flow ratio can also improve the cell performance. As the oxygen concentration becomes zero in about 8 percent depth of cathode catalyst layer, the thickness of cathode catalyst layer can be reduced 92 percent without any potential loss in output voltage. The cathode activation loss also becomes high by increasing the molar fraction of nitrogen gas. The modeling results agree very well with experimental results.