A novel constitutive stress-strain law for compressive deformation of the gas diffusion layer

Substantial compressive deformation occurs in the gas diffusion layer (GDL) under the pressure applied during the fuel cell assembly. The GDL deformation has a direct impact on the efficiency and performance of the fuel cell since it leads to the alteration of the GDL microstructure and porosity. This makes the accurate characterization of the GDL compressive behavior crucial for analyzing the fuel cell performance and its optimal design. In this paper, analytical, experimental, and numerical methods have been employed to comprehensively study the constitutive law of the GDL under compression. Starting from the recently developed stress-density relations, the constitutive stress-strain equations are derived for the GDL and the relation between the stress-density and stress-strain laws are revealed. Experimental compression tests have been performed on GDL samples and the capability of the proposed constitutive law in capturing the real behavior of the material has been proved. It has been observed that the simplifying assumption of constant zero Poisson's ratio in the through-plane direction made in many previous studies cannot accurately represent the GDL material behavior and a modification is proposed. The developed constitutive law has been successfully implemented in a finite element model of the GDL-bipolar plate assembly in the fuel cell structure and the variations of the GDL porosity, density, and through-plane Young's modulus and Poisson's ratio have been investigated for different vertical displacements of the bipolar plate.