Gas Diffusion Layer Research Articles

Toward revolutionizing PEMFC manufacturing for clean energy conversion: a review on the innovative contribution of 3D printing techniques

AbstractThree-dimensional printing (3DP) is a technology useful for fabricating both structural and energy devices. Of great concern to this review is promising nature of additive manufacturing (AM) for engineering fuel cells (FCs) for clean energy conversion. 3DP technique is useful for the fabrication of fuel cell components, and they offer waste minimization, low-cost, and complex geometric structures. In this review, significance of different 3DP techniques toward revolutionizing fuel cell fabrication is given. The aim is to unravel the importance and status of 3D-printed fuel cells and hence provides researchers and scientists with extensive opportunities of 3DP techniques for fuel cell engineering. After careful selection of state-of-the-art literatures, different kinds of 3DP techniques of relevance to electrolytes, electrodes, and other key components (e.g., gas diffusion layers (GDLs), bipolar plates (BPs), and membrane electrode assembly (MEA)) fabrication are explicitly discussed. Among the techniques, the best approaches are recommended for further studies. Advantages associated with these techniques are indicated for the benefit of those whose interests matter most on clean energy production. The challenges researchers are facing in the use of 3DP for fuel cell fabrications are identified. Possible solutions to the identified challenges are suggested as way forward to further development in this research area. It is expected that this review article will benefit engineers and scientists who have interest on clean energy conversion devices.

CATALYST BASED ON PALLADIUM‐MODIFIED MIL‐53(AL) PYROLYSATE FOR ORR IN ALKALINE MEDIA

A catalyst for the oxygen reduction reaction (ORR) based on the metal‐organic framework material MIL‐53(Al) modified with palladium was synthesized. Its textural and morphological characteristics were studied using the method of adsorption porosimetry, SEM, TEM, energy dispersive X‐ray analysis (EDAX) , X‐ray diffraction (XRD), Raman –spectroscopy, X‐ray photoelectron spectroscopy (XPS) and thermogravimetric analysis (TGA‐DSC). The electrocatalytic properties of the synthesized material in ORR were studied by voltammetry using a rotating disk electrode. Corrosion resistance was studied in the CV mode. It was found that the synthesized catalyst is characterized by high corrosion resistance. The tolerance of synthetized catalyst Pyr_MIL‐53(Al)_Pd to the methanol was studied. The obtained catalyst was studied in a membrane electrode assembly (MEA) formed by spraying an ionomer suspension onto a gas diffusion layer (GDL). The synthesized Pyr‐MIL‐53 (Al)_Pd and commercial platinum (60% Pt) (HiSPEC 9100) catalysts were compared in the cathode composition, and 10% PtM (M = Ni, Mo)/CNT catalysts were used on the anode. The power density of the FC (P) was calculated based on the obtained current‐voltage curves. Based on the set of characteristics, the synthesized catalyst based on MIL‐53 (AL) doped with palladium is superior in efficiency to the commercial platinum catalyst.

Numerical Model for Investigating Effects of Cracks and Perforation on Polymer Electrolyte Fuel Cell Performance

The presence of cracks in the microporous layer (MPL) of polymer electrolyte fuel cells (PEFCs), often occurring during the membrane electrode assembly manufacturing process, has a significant impact on cell performance. However, the exact influence of crack presence, density, and patterns within MPLs on cell performance and transport behaviors remains unclear. This study introduces a three-dimensional macroscale model of PEFCs aimed at investigating the effects of MPL cracks and gas diffusion layer (GDL) perforations on cell performance and transport behavior. This model offers several advantages, including the ability to potentially integrate the effects of flow channel design in future. Additionally, the model can seamlessly incorporate electrochemical reactions and explore phenomena within the catalyst layers (CLs), expanding simulation capabilities beyond water transport alone. The findings suggest that MPL cracks contribute positively to performance by facilitating water drainage. Furthermore, when combined with perforations in GDLs, MPL cracks can significantly enhance performance by providing pathways for water transport. Overall, this study provides valuable insights into developing models for optimizing PEFC performance and underscores the need for further research and development in this area.

Numerical investigation of PEMFC performance enhancement through combined design of anodic fishbone ridge groove channel and optimal gas diffusion layer porosity gradient

The flow field plate is one of the core components of proton exchange membrane fuel cells (PEMFC), and its structure significantly influences the thermo-electrochemical coupling transport characteristics of PEMFCs. Optimizing the parameters of the flow channels of bipolar plates is crucial for enhancing the mass transfer of reacting gas and improving water removal capacity. In this study, an anodal fishbone ridge groove combined flow channel (F-SFC) is designed to enhance the diffusion uniformity of anode hydrogen gas, and a 3D multi-phase model of PEMFC is established using the multiphysics simulation software COMSOL Multiphysics. The F-SFC was compared with traditional bipolar plates featuring symmetric anode and cathode flow channels in terms of overall output performance, and the results are presented. The findings indicate that the F-SFC design achieves an average increase of 28.78% in current density and 21.07% in power density compared to conventional fishbone flow channels. When compared to traditional serpentine flow channels, the F-SFC design shows a 13.5% increase in current density and a 10.42% increase in power density. Furthermore, adding multilayer porosity gradients to gas diffusion layers (GDLs) greatly improves internal mass transfer. A gradient porosity of 0.7, 0.5, and 0.3 along the Z-axis produces a more equal distribution of current density and water concentration on the membrane. This work sheds fresh light on optimizing PEMFC design for increased power density, providing useful theoretical advice for future advances.

Deep learning based segmentation of binder and fibers in gas diffusion layers

Gas diffusion layers (GDLs) are vital parts for the performance of proton-exchange membrane fuel cells (PEMFCs). In many cases, they are made of Carbon-Carbon Composite Paper (CCCP), which consists of carbon fibers and a carbonized binder material. The distribution of the fibers and binder in the GDL strongly influences the performance of a PEMFC. Synchrotron scans are a great way to obtain information about the microstructural composition of carbon paper GDLs (Figure 2), but there is one major obstacle. Binder and fibers tend to have the same attenuation and, consequently, the same gray values in the scans. To overcome this, we introduce a machine learning-based method that segments fibers and binder from the local morphology of a CCCP. The training data is generated using FiberGeo, a module in the GeoDict software for fibrous microstructure generation. FiberGeo creates fibers based on stochastic geometry and adds binder using morphological opening and closing operations. We applied the machine learning-based method to four Scans of samples of Toray Carbon Paper with varying amounts of binder in them. The result is the quantification of individual voxels as fiber or binder material that can be used, for example, in performance simulations of property simulations in PEMFCs [1–4]. Here, we focus on the differences in the spatial distribution of the binder both in the through-plane and in-plane directions.

Effects of droplet dynamical behavior in flow channel of proton exchange membrane fuel cell under vibration conditions on cell performance

Proton exchange membrane fuel cells are subjected to severe vibration in aerospace applications. Understanding the droplet transport characteristics in the flow channelunder vibration conditions is essential for improving cell performance. However, the underlying patterns and mechanisms of the vibration effects on cell performance and its internal water transport remain unclear, and there is a lack of improvement methods for drainage under vibration conditions. This study experimentally investigates the effect of vibration on cell performance. Experimental results indicate that vibration predominantly affects cell performance through its modulation of water transport. Therefore, the droplet dynamic behavior in the flow channel is further studied using the volume of fluid method. The results indicate that vibrations can enhance the average performance of the fuel cells, with the largest increase of 8.30 %. This is attributed to vibrations promoting the detachment of droplets from the gas diffusion layer surface and reducing the water coverage ratio on said surface. Under conditions of low gas velocity, high surface hydrophobicity, and large droplet size, droplets exhibited oscillatory and jumping behavior in the flow channel due to vibration, resulting in the largest 53.5 % increase in peak water coverage ratio on the gas diffusion layer surface compared to no-vibration conditions. Furthermore, enhancing the hydrophobicity of the gas diffusion layer and the hydrophilicity of the channel walls promotes droplet detachment and discharge compared to no-vibration, as well as contributing to the improvement of vibration effects on the drainage process.

Electrochemical activation and characterization of carbon cloth

Here, carbon cloth (CC), which is a disposable, inexpensive, conductive substrate, was electrochemically activated for the formation of function al groups on the electrode surface. The electrochemical activation of commercial CC was achieved in various acidic solutions such as 0.1 M H2SO4, 0.1 M HCl and 0.1 M HNO3 to create functional groups on the surface of the gas diffusion layer by applying a constant 100 mA current (galvanostatic) for 10 s, 20 s, and 30 s, respectively. The electrochemical measurements were conducted using a 3-electrode system, including disposable carbon cloth as a working electrode, saturated Ag/AgCl as a reference electrode and Pt wire as a counter electrode. The modified CCs were tested via cyclic voltammetry using 5 mM Fe(CN)63−/Fe(CN)64− redox probe. Electrochemical experiment results showed that acid treatment of CC resulted in a significant increase in peak current compared to bare CC, indicating formation of functional groups on the electrode surface and improved electrical conductivity.

Liquid Water Transport and Distribution in the Gas Diffusion Layer of a Proton Exchange Membrane Fuel Cell Considering Interfacial Cracks

The proton exchange membrane fuel cell (PEMFC), with a high energy conversion efficiency, has become an important means of hydrogen energy utilization. However, water condensation is unavoidable in the PEMFC because of low operating temperatures. The impact of liquid water on PEMFC performance and stability is significant. The gas diffusion layer (GDL) provides a critical transport path for liquid water in the PEMFC. Liquid water saturation and distribution in the GDL determine water flooding and mass transfer efficiency in the PEMFC. In this study, focusing on the effects of the water introduction method, osmotic pressure, and contact angle, the liquid water transport in the GDL was numerically investigated based on a pore-scale model using the volume of fluid (VOF) method. The results showed that compared with the conventional water introduction method without cracks, the saturation and spatial distribution of water inside the GDL obtained in the simulation were more consistent with the experimental results when the water was introduced through the microporous layer (MPL) crack. It was found that increasing the osmotic pressure resulted in a faster rate of water penetration, faster approaching the steady-state performance, and higher saturation. The ultra-high osmotic pressure contributed to the secondary breakthrough with a significant increase in saturation. Increasing the contact angle caused higher capillary resistance, especially in the region with small pore sizes. At a constant osmotic pressure, as the contact angle increased, the liquid water gradually failed to penetrate into the small pores around the transport path, causing saturation reduction and an ultimate failure to break through the GDL. Increasing the contact angle contributed to a higher breakthrough pressure and secondary breakthrough pressure.

Effect of the Cathodic Gas Diffusion Layer on the Performance of a Proton Exchange Membrane Electrolyzer

Hydrogen production through electrolysis using renewable resources is highly promising for reducing greenhouse gas emissions. While significant efforts have focused on developing more efficient and cost-effective catalysts to lower hydrogen production costs, catalysts are not the primary expense in electrolyzer fabrication. In the case of Proton Exchange Membrane Water Electrolyzers (PEMWEs), other components—such as the proton membrane, gas diffusion layer (GDL), and bipolar plates—contribute more to overall costs. To explore this, a study was conducted on the performance of PEMWEs with various carbon paper GDLs, developed in the lab, on the cathodic side. This study examined how properties like electrical conductivity, porosity, and gas permeability affect performance. These findings emphasize the need to optimize components beyond catalysts to improve the cost-effectiveness of hydrogen production through electrolysis.

Development of Grooves in Gas Diffusion Layers for PEM Fuel Cells Considering Mechanisms of Oxygen Transport and Water Drainage

Development of Grooves in Gas Diffusion Layers for PEM Fuel Cells Considering Mechanisms of Oxygen Transport and Water Drainage

High Safety Fuel Cells Based on Gas Diffusion Layer Suppressed Uneven Current and Thermal Runaway

AbstractThermal runaway poses a critical safety concern for fuel cells, significantly impairing their performance and durability. Uneven current often leads to uneven temperature, exacerbating the risk of thermal runaway. The inadequate electrical and thermal conductivity of the gas diffusion layer (GDL) is identified as the primary cause of the safety issues. To address this, a multilayer composite gas diffusion layer (MC‐GDL) is proposed and designed to enhance both electrical and thermal conductivity. The in‐plane electrical conductivity of the MC‐GDL reaches an impressive 9.1 × 104 S m−1. Under extreme uneven current, the fuel cell's performance with MC‐GDL only declines by 3.7%, compared to a substantial 58.1% decline observed with commercial GDL. Additionally, the in‐plane thermal conductivity of the MC‐GDL is notably high at 337.0 W m−1 K−1. Under extreme uneven temperature, the maximum temperature of Nafion membrane in fuel cell equipped with MC‐GDL is only 84.2 °C significantly lower than the 180.7 °C observed with commercial GDL. Consequently, the MC‐GDL effectively prevents the melting, thinning, and perforation of the Nafion membrane, thereby mitigating thermal runaway. Furthermore, the superior electrical and thermal conductivity of MC‐GDL can enhance the safety of other electrochemical devices by minimizing uneven current and thermal runaway.

Clamping Pressure and Catalyst Distribution Analyses on PEMFC Performance Improvement

The coupling effects of clamping pressure and catalyst distribution are comprehensively considered to improve proton exchange membrane fuel cell (PEMFC) performance. Numerical models were constructed to study the performance changes and the corresponding internal states of PEMFC under different clamping pressures. Since the increased clamping pressure reduces the uniformity of current density, non-uniform designs with decreased catalyst loading under channel and increased catalyst loading under rib are proposed for performance improvement. A weighted objective function considering current density magnitude and uniformity was constructed, and the performances of different catalyst loading distributions were analyzed. Compared to the uniform distribution, the optimized distribution with a variation of −15% and 15% under channel and rib had the maximum objective function value of 17.24%. The deformation analysis of the gas diffusion layer and optimization of catalyst loading distribution based on deformation analysis provided a reference for the assembly of PEMFC and the production of MEA.

Simultaneous accelerated stress testing of membrane electrode assembly components in polymer electrolyte fuel cells

The durability of polymer electrolyte fuel cells (PEFCs) in fuel cell electric vehicles is important for the shift from passenger cars to heavy-duty vehicles. The components of a PEFC, namely the proton exchange membrane (PEM), catalyst layer (CL), and gas diffusion layer (GDL), contribute to the degradation of the fuel cell performance. In this paper, we propose a method for simultaneously evaluating the degradation rates of these components by combining electrochemical characterization with operando synchrotron X-ray radiography. The open-circuit voltage, electrochemically active surface area (ECSA), and water saturation were used as the degradation indicators for the PEMs, CLs, and GDLs, respectively. The results of two accelerated stress tests (loading and start-stop cycles) after 10,000 cycles showed that the increase in water saturation owing to the loss of hydrophobicity due to carbon corrosion in the cathode GDL occurred on the same timescale as the degradation in the PEM and cathode CL. Specifically, during the load cycle AST, the cathode CL degraded with a 26% reduction in the ECSA along with the cathode GDL degradation with a 10% increase in water saturation. This suggests that more efforts should be devoted to studies on the durability of GDLs for heavy-duty applications.

Study of the effect of pore properties of microporous layer on water transport process in proton exchange membrane fuel cell

Aiming at the “water flooding” phenomenon inside the Gas Diffusion Layer (GDL) of the Proton Exchange Membrane Fuel Cell (PEMFC), this paper visualizes the effects of the pore properties and gradient structure of the microporous layer (MPL) on water transport. Specifically, we visualize the impact of pore properties and gradient structure on water transport. For this purpose, a liquid water capillary finger advancement visualization test platform is constructed to analyze the evolution of liquid water in the porous medium and reveal the effects of single porosity, single pore diameter, gradient porosity, and gradient pore diameter of the MPL on the liquid water transport. Moreover, the time of the non-wetting liquid touching the top, the maximum spreading length, and the residual volume in the MPL are analyzed to evaluate the drainage capacity. The results highlight that the microporous layer's smaller porosity and pore size could limit the interface's extended width between the microporous and gas diffusion layers. Additionally, the residual volume of non-wetting liquid is 21.6 % less in the case of φ = 0.3 than for φ = 0.45, and the residual volume of non-wetting liquid is 11.8 % less in the case of d = 0.82 mm compared to d = 2.45 mm. Furthermore, the residual volume of the microporous layer in the Catalyst layer (CL) side of the microporous layer is 11.8 % less than that in the case of d = 2.45 mm. Finally, we conclude that when the pore gradient law is opposite, it is unfavorable for liquid water discharge.

Engineering potential electrocatalysts for both AEM Electrolyzers and Redox Flow Batteries: Design of experiments at the different scales

Both water electrolysis and electrochemical energy storage are promising technologies for dealing with the intermittency of green electricity generation. In this work we investigated the possibility of using the same electro-catalyst for hydrogen production by Anion Exchange Membrane Water Electrolysis (AEMWE) and energy storage by Redox Flow Batteries (RFB). A complete experimental campaign was designed to investigate the effects of the catalyst nanostructure and morphology on the electrode performance at different scales. Focus was devoted to the choice of the main factors influencing the catalyst structure, its morphology and electrochemical activity; taking further into account the technique to deposit the catalyst on the Gas Diffusion Layer (GDL) and its integration inside the Membrane Electrode Assembly (MEA). Some results are reported for a spinel-based NiCo2O4 catalyst, chosen as a base nanocomposite to develop more complex materials for both the Oxygen Evolution Reaction (OER) in AEMWE and the positive electrode in Vanadium RFB in the future.

Two-Phase Fluid Dynamics in Proton Exchange Membrane Fuel Cells: Counter-Flow Liquid Inlets and Gas Outlets at the Electrolyte-Cathode Interface

Understanding the counter-flow of liquid inlet and gas outlet at the interface between the electrolyte and cathode gas diffusion layer (GDL) is crucial for water management in proton exchange membrane fuel cells. Existing studies typically overlook air outlets and assume a fixed liquid inlet direction. This study uses a volume of fluid method to model two-phase interactions in a T-shaped GDL and gas channel (GC) assembly, with GDL geometry derived from nano-computer tomography. Considering potential electrode deformations, such as local cracks and blockages, this research investigates the impact of the size and shape of liquid invasion on the liquid-gas behavior in the cathode GDL and GC using five liquid injection configurations. Simulations also incorporate GDL gas outlets, integrating them with a tailored liquid inlet setup. Results show that the injection site and configuration significantly affect water behavior in the GDL, affecting saturation, stabilization, and breakthrough, followed by drainage in the GCs. Comparisons of simulations with and without air outflow show distinct counter-flow interactions, highlighting variations in water distribution and discrepancies in two-phase transport across the GCs.

In situ synthesis and deposition of palladium nanoparticles on gas diffusion layers via gamma radiolysis for cathode electrodes in proton exchange membrane fuel cells

This study investigates gamma radiolysis technique for synthesising and depositing palladium (Pd) nanoparticles on gas diffusion layers (GDLs). The Pd-coated GDLs were then used to fabricate MEAs, which were evaluated for their single-cell performance. The fabricated PEMFCs with Pd-loaded GDLs successfully generated potential and produced electricity, with the PEMFC with a Pd-loaded GDL prepared using a 0.05 M Pd precursor solution and 50 KGy dose achieved performances comparable to the PEMFC with commercial gas diffusion electrodes (GDEs). This study represents the first demonstration of a functional PEMFC using a novel gamma radiolysis-synthesised Pd catalyst GDL as the cathode electrode.

Development of optimal energy management strategy for proton exchange membrane fuel cell-battery hybrid system for drone propulsion

Drones powered by fuel cells have been developed to ensure long flight distances. Due to the low dynamic responsiveness of proton exchange membrane fuel cell (PEMFC) systems, they must be integrated with batteries to fully meet the power demand profiles of drones. In this study, a dynamic model of a PEMFC-battery hybrid system for drone propulsion is developed in MATLAB-Simulink® to establish the optimal energy management strategy (EMS) for ensuring efficient and safe operation. The proposed PEMFC system comprises two modules of an open-cathode PEMFC stack, which are connected in parallel. To estimate the dynamic behavior and performance of PEMFC, one-dimensional dynamic model of PEMFC considering two-phase transport through the gas diffusion layer is developed and simulated. A zero-dimensional dynamic model of the battery was also developed based on an equivalent circuit model. The resulting PEMFC-battery hybrid system model was simulated to determine the power required for the propulsion of the drone according to a flight scenario comprising five phases: takeoff hover, climb, cruise, descent, and landing hover. Three different EMSs are developed and simulated to define the optimal one for the PEMFC-battery hybrid system by comparing the total hydrogen consumption and the final SOC of the battery As a result, the EMS that equally splits the required power between two PEMFCs exhibits the lowest hydrogen consumption during the flight simulation. This study helps provide the optimal system design and control scheme of drones powered by fuel cells.

Enhanced CO2 Electroreduction to ethylene on Cu nanocube coated with nitrogen-doped carbon shell in-situ electro-derived from metal-organic framework

Electrochemical CO2 reduction reaction (CO2RR) to ethylene is one of the most promising technologies to achieve efficient use of carbon resources and sustainable development, in which the development of an efficient and stable electrocatalyst is particularly important. In this work, we develop a catalyst in situ electro-derived from Cu-based MOF for CO2RR to ethylene. We prepared nano Cu-MOF by microwave synthesis and supported it on a Cu foil substrate as a working electrode (denoted as MOF/Cu foil). During in situ electrolysis, Cu-MOF was converted into a highly dispersed nitrogen-doped carbon-coated Cu nanocube (denoted as Cu-cube/CN), which inhibited particle agglomeration and enhanced active site exposure. At a potential of −1.15 V vs. RHE, the Faradaic efficiency (FE) of the Cu-cube/CN catalyst for ethylene is 49.6 %, significantly higher than that of the original Cu foil electrode and Cu-MOF supported on the gas diffusion layer (GDL) prepared working electrode (denoted as MOF/GDL). In situ attenuated total reflection surface-enhanced infrared absorption spectroscopy (ATR-SEIRAS) and density functional theory (DFT) calculations studies indicate that due to the electron-donating ability of the CN coating, the adsorption of *CO is enhanced, increasing the *CO coverage, lowering the reaction free energy of *CO dimerization, promoting C-C coupling and ethylene generation. This work provides new insights for the development of efficient and stable electrocatalysts for CO2RR-to-ethylene production.

Effects of Sodium Chloride on PEMFC Durability at a Concentration Close to that of a Marine Environment

The marine application of proton exchange membrane fuel cells (PEMFCs) requires special attention due to sea salt aerosols and atmospheric pollutants, susceptible to degrade these systems and induce performance losses. To the best of our knowledge, this study is the first to identify the performance losses of PEMFCs due to sodium chloride (NaCl) pollution similar to that of the marine environment. A 641 h ageing test with a NaCl concentration in air of 120 μg.m‒3 was carried out on a five cells stack of 220 cm2. The results reveal a key mechanism for reversible performance loss, namely the deposition of salt particles in the channels and on the surface of the cathode gas diffusion layer (GDL). This can lead to the complete shutdown of a cell. Nonetheless, this contamination did not induce significant irreversible performance losses as the restarts of the stack cause the salt particles to dissolve. An overall degradation rate of 8 μV·h‒1, similar to that of the baseline without NaCl contamination, is observed.