Dynamic operational power demands from a fuel cell, especially in transportation applications, are known to causefluctuations in its relative humidity (RH) and temperature [1]. This leads to repetitive in-plane compressive and tensile stress build-up in the confined perfluorosulfonic acid (PFSA) ionomer membranes due to constraining of their cyclic swelling and shrinkage under hydrated and dehydrated states, respectively. The ionomer’s dynamic water sorption characteristics during these hygrothermal variations lead to catalyst coated membrane (CCM) deformation and cyclic mechanical stresses resulting in structural fatigue and micro-crack development at high stress accumulation sites [2]. Lately, laboratory-based X-ray computed tomography (XCT) was used for non-destructive four-dimensional (4D) visualization and microstructural analysis of fuel cell parts showing novel insights on their failure processes [3,4]. The objective of the present work is to leverage 4D XCT visualization to design and demonstrate novel mitigation strategies for mechanical membrane degradation in fuel cells. A custom designed X-ray transparent fixture housing a small-scale single cell fuel cell was subjected to 2 min. each of wet and dry cycles with N2 gas at anode and cathode compartments, thereby causing fatigue-based membrane damage [5]. 3D tomographic data sets of same membrane electrode assembly (MEA) locations were acquired as a function of degradation time, which facilitated to study the damage development and growth. As a baseline for this work, a non-bonded MEA with high surface roughness gas diffusion layers (GDLs) demonstrated that the primary membrane failure mode was CCM buckling into GDL voids/pores [6]. To overcome this failure mode, two separate mitigation approaches are explored in the present work: (i) a commercial GDL with low surface roughness; and (ii) bonding of MEA to arrest buckling. Furthermore, a multi-physics finite element method (FEM) model is developed to simulate the contact interaction at the catalyst layer | GDL interface and non-uniformity in the GDL microstructure. The XCT findings are correlated with the numerical model to perceive the specific impact of GDL surface features on the development and distribution of membrane failures.Similar to the baseline MEA, membrane crack development was observed to be the key failure mode for both mitigation approaches. When the two mitigation designs are compared at similar cycling stages with the baseline (Fig. 1), however, the size and density of membrane cracks is drastically reduced. Since both mitigation strategies are tested using the same accelerated stress test protocol as the baseline, it is hereby established that each approach provides substantial mitigation against fatigue driven mechanical membrane degradation, predominantly due to reduced severity of CCM buckling deformation, resulting in a doubling of the membrane lifetime in each case. Complementary finite element simulations corroborate the experimental findings and further estimate the critical GDL void sizes to prevent CCM buckling and the required interfacial MEA adhesion quality to stabilize the MEA for overall membrane durability. Acknowledgements Funding for this research was provided by the Natural Sciences and Engineering Research Council of Canada, Canada Foundation for Innovation, British Columbia Knowledge Development Fund, and Ballard Power Systems through an Automotive Partnership Canada grant. This research was undertaken, in part, thanks to funding from the Canada Research Chairs program.
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