Challenges remain with the accurate modeling and optimization of gas transport in polymer electrolyte membrane fuel cells (PEMFCs) due to the complexity of calculating transport across the relevant domains and structures in a fuel cell. Each cell comprises two bipolar plates (BPPs) compressed around a membrane electrode assembly (MEA). The bipolar plates (BPPs) are a multifunctional component having flow fields with mm-sized features designed for reactant delivery and heat and water management. The MEA comprises a 5-layer structure with microporous catalyst and gas diffusion layers (GDLs) on either side of a proton exchange membrane (PEM). Actual cell designs are further constrained by their materials, and manufacturing cost and speed.Prior work primarily focuses on modeling the flow fields in metal BPPs as idealized geometries, neglecting the inherent curvature introduced during the stamping manufacturing process and the compression and thickness variation of the MEA layers. To create high-performance cells, it is necessary to understand the detailed interaction of the BPPs and MEAs in practical, manufactured fuel cell stacks.In this work, a compressed short stack of unit cells from a decommissioned commercial fuel cell electric vehicle (FCEV) was resolved in three dimensions (3-D) using a micro-computed tomography instrument (micro-CT) capable of imaging large samples (up to 30 cm). Representative images from across the cell domains are shown in Figure 1. The 3-D images were subsequently segmented and meshed for computational fluid dynamics (CFD) modeling. Simulations of transport and electrochemical phenomena were performed using commercial CFD software using custom codes. Simulation results were used to assess the performance of a mesh-type cathode flow field design with secondary flows as well as the impact of compression, and stamped plate curvature. The results highlight the significant impact of the induced convective transport in the gas diffusion layers (GDLs) has on the performance of a practical fuel cell.Acknowledgements: This material is based upon work supported by Plug Power Incorporated.Figure Collage: Left – 3D Micro-CT Images of the BPPs and components of an MEA, Center - Meshing faces, Right – Relative Humidity Profile Figure 1
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