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A pore network model (PNM) is proposed for the simulation of water transport inside the cathode side ‎gas diffusion layer (GDL) of polymer electrolyte fuel cells (PEFCs) during the transient start-up period as ‎well as the steady state. Numerous two-dimensional random networks representing GDL are generated ‎followed by statistical averaging of the results (Monte Carlo methods) to circumvent the uncertainties ‎imposed by random pore size distributions. The resulting liquid water saturation profiles within GDLs ‎exhibit concave patterns which is typically encountered in capillary fingering flow regimes in porous ‎media. The effect of GDL thickness and current collector rib width as two geometric parameters on water ‎transport dynamics are separately investigated. It turns out that thin and thick GDLs compared to the base ‎case can have contradicting outcomes on the account of total water saturation in the network. On the ‎other hand, wide current collector ribs give rise to liquid water saturation and build-up within GDL which ‎can lead to flooding. At the end, three-dimensional networks are generated demonstrating higher pore ‎connectivity which results in higher percolation times and different invasion patterns.‎

Proton exchange membrane fuel cells (PEMFCs) are an attractive type of fuel cell that have received successful commercialization, benefitted from its unique advantages (including an all solid-state structure, a low operating temperature and low environmental impact). In general, the structure of PEMFCs can be regarded as a sequential stacking of functional layers, among which the gas diffusion layer (GDL) plays an important role in connecting bipolar plates and catalyst layers both physically and electrically, offering a route for gas diffusion and drainage and providing mechanical support to the membrane electrode assemblies. The GDL commonly contains two layers; one is a thick and rigid macroporous substrate (MPS) and the other is a thin microporous layer (MPL), both with special functions. This work provides a brief review on the GDL to explain its structure and functions, summarize recent progress and outline future perspectives.

The mitigation of water flooding in the gas diffusion layer (GDL) at relatively high current densities is indispensable for enhancing the performance of proton exchange membrane fuel cells (PEMFCs). In this paper, a 2D multicomponent LBM model is developed to investigate the effects of porosity distribution and compression on the liquid water dynamic behaviors and distribution. The results suggest that adopting the gradient GDL structure with increasing porosity along the thickness direction significantly reduces the breakthrough time and steady–state total water saturation inside the GDL. Moreover, the positive gradient structure reaches the highest breakthrough time and water saturation at 10% compression ratio (CR) when the GDL is compressed, and the corresponding values decrease with further increase of the CR. Considering the breakthrough time, total water saturation and water distribution at the entrance of the GDL at the same time, the gradient structure with continuously increasing porosity can perform better water management capacity at 30% CR. This paper is useful for understanding the two–phase process in a gradient GDL structure and provides guidance for future design and manufacturing.

Hydrogen is considered to be the fuel of the future and with the advancement of fuel cell technology, there is a renewed interest in hydrogen production by the electrolysis of water. Among low-temperature water electrolysis options, polymer electrolyte membrane (PEM) electrolyzer is the preferred choice due to its compact size, intermittent use, and connectivity with renewable energy. In addition, it is possible to generate compressed hydrogen directly in the PEM electrolyzer, thereby reducing the additional pressurization cost for hydrogen storage. The development of electrocatalysts for oxygen evolution reaction (OER) and hydrogen evolution reaction (HER) is a major focus of electrolysis research. Other components, such as PEMs, gas diffusion layers (GDL), and bipolar plates (BPs) have also received significant attention to enhance the overall efficiency of PEM electrolyzers. Improvements in each component or process of the PEM electrolyzer have a significant impact on increasing the energy efficiency of the electrolyzer. This work discusses various synthesis techniques to improve the dispersion of OER electrocatalyst and reducing catalyst loading for the PEM electrolyzer. Various techniques are discussed for the development of electrocatalysts, including nanostructured, core shell, and electrodeposition to deposit catalysts on GDL. The design and methodology of new and improved GDL are discussed along with the fabrication of gas diffusion electrodes and passivation techniques to reduce the oxidation of GDL. The passivation technique of BPs using Au and Pt is summarized for its effect on electrolysis efficiency. Finally, the optimization of various operating conditions for PEM electrolyzer are reviewed to improve the efficiency of the electrolyzer.

The consumption of hydrogen could increase by sixfold in 2050 compared to 2020 levels, reaching about 530 Mt. Against this backdrop, the proton exchange membrane fuel cell (PEMFC) has been a major research area in the field of energy engineering. Several reviews have been provided in the existing corpus of literature on PEMFC, but questions related to their evolutionary nuances and research hotspots remain largely unanswered. To fill this gap, the current review uses bibliometric analysis to analyze PEMFC articles indexed in the Scopus database that were published between 2000–2021. It has been revealed that the research field is growing at an annual average growth rate of 19.35%, with publications from 2016 to 2012 alone making up 46% of the total articles available since 2000. As the two most energy-consuming economies in the world, the contributions made towards the progress of PEMFC research have largely been from China and the US. From the research trend found in this investigation, it is clear that the focus of the researchers in the field has largely been to improve the performance and efficiency of PEMFC and its components, which is evident from dominating keywords or phrases such as ‘oxygen reduction reaction’, ‘electrocatalysis’, ‘proton exchange membrane’, ‘gas diffusion layer’, ‘water management’, ‘polybenzimidazole’, ‘durability’, and ‘bipolar plate’. We anticipate that the provision of the research themes that have emerged in the PEMFC field in the last two decades from the scientific mapping technique will guide existing and prospective researchers in the field going forward.

At present, the proton exchange membrane fuel cell (PEMFC) is one of the most promising new energy solutions. The structure and material properties of the gas diffusion layer (GDL) are important factors that restrict the efficient water management and structural stability of PEMFCs. The complex mesoscopic fibrous porous structure of the GDL results in complex multiphase flow dynamics problems that have highly nonlinear characteristics. It is difficult to describe the details of mesoscopic multiphase coupled transport dynamics and numerically solve problems in which there is a two-phase flow with a high-density ratio. To solve these problems, a mesoscopic multiphase coupled transport model based on a lattice Boltzmann method and volume-of-fluid (LBM-VOF) model is proposed. Moreover, we also discuss the mechanism of the interaction between the fibrous porous structure and internal multiphase flow. The results obtained illustrate that the proposed method can obtain dynamic details of the flow field for fibrous porous media. The surface wettability of fibres strongly influences both the distribution and stability of liquid water clusters within porous materials. Concurrently, the fibre diameter assumes a pivotal role in governing lateral water diffusion and exclusion efficiency. This work lays a foundation for efficient water and thermal management of PEMFCs.

Gas diffusion layer (GDL) plays a very important role in the proton exchange membrane fuel cell (PEMFC), and changing the GDL structure becomes a good way to improve the PEMFC performance. GDL with different perforation diameters and perforation depths are established by the stochastic reconstruction method. The perforation filling amount is introduced to simulate the reservoir effect of the perforated structure, and the lattice Boltzmann method (LBM) is used to computationally study the gas transport performance within the perforated GDL. The results show the perforated structure can significantly improve the gas transport performance, and the influence on each porosity structure varies when containing different perforated filling amounts. When the porosity is larger, the effective diffusion coefficient of perforated structure is lower than that of non-perforated structure with less filling amount. The calculation of anisotropic permeability reveals that the through-plane permeability is greater than the in-plane permeability when the perforation reaches a certain depth, and the optimal perforation diameter and depth in each structure are analyzed from the perspective of maximizing the average permeability in the through-plane direction. Article highlights The complete structure of the gas diffusion layer was stochastic reconstructed and perforated. The effects of different perforation structures on the gas transport properties were mainly investigated by Lattice Boltzmann method, and the presence of a homogeneous filler inside the perforation was considered. The optimal parameters of different perforated structures and GDL porosity structures were compared and analyzed.

Fuel cells (FCs) have received huge attention for development from lab and pilot scales to full commercial scale. This is mainly due to their inherent advantage of direct conversion of chemical energy to electrical energy as a high-quality energy supply and, hence, higher conversion efficiency. Additionally, FCs have been produced at a wide range of capacities with high flexibility due to modularity characteristics. Using the right materials and efficient manufacturing processes is directly proportional to the total production cost. This work explored the different components of proton exchange membrane fuel cells (PEMFCs) and their manufacturing processes. The challenges associated with these manufacturing processes were critically analyzed, and possible mitigation strategies were proposed. The PEMFC is a relatively new and developing technology so there is a need for a thorough analysis to comprehend the current state of fuel cell operational characteristics and discover new areas for development. It is hoped that the view discussed in this paper will be a means for improved fuel cell development.

In this paper, we report the preparation of a gas diffusion layer (GDL) with different gradient pore size structures. The pore structure of microporous layers (MPL) was controlled by the amount of pore-making agent sodium bicarbonate (NaHCO3). We investigated the effects of the two-stage MPL and the different pore size structures in the two-stage MPL on the performance of proton exchange membrane fuel cells (PEMFC). The conductivity and water contact angle tests showed that the GDL had outstanding conductivity and good hydrophobicity. The results of the pore size distribution test indicated that introducing a pore-making agent altered the pore size distribution of the GDL and increased the capillary pressure difference within the GDL. Specifically, there was an increase in pore size within the 7–20 μm and 20–50 μm ranges, which improved the stability of water and gas transmission within the fuel cell. The maximum power density of the GDL03 was increased by 37.1% at 40% humidity, 38.9% at 60% humidity, and 36.5% at 100% humidity when compared to the commercial GDL29BC in a hydrogen-air environment. The design of gradient MPL ensured that the pore size between carbon paper and MPL changed from an initially abrupt state to a smooth transition state, which significantly improved the water and gas management capabilities of PEMFC.

Proton exchange membrane fuel cells (PEMFCs) have been recognized as a promising power generation source for a wide range of automotive, stationary, and portable electronic applications. However, the durability of PEMFCs remains as one of the key barriers to their wide commercialization. The membrane electrode assembly (MEA) as a central part of a PEMFC, which consists of a proton exchange membrane with a catalyst layer (CL) and gas diffusion layer (GDL) on each side, is subject to failure and degradation in long-running and cycling load conditions. The real-time monitoring of the degradation evolution process through experimental techniques is challenging. Therefore, different numerical modeling approaches were proposed in the literature to assist the understanding of the degradation mechanisms in PEMFCs. To provide modeling progress in the addressed field, this paper briefly discusses the different degradation mechanisms occurring in the MEA. In particular, we present a detailed review of MEA degradation modeling research work, with special attention paid to the physical-based models (mechanistic models). Following the most recent relevant literature, the results showed that the combination of microstructure component models with macro-scale comprehensive PEMFC models provides a better understanding of degradation mechanisms when compared to single-scale degradation models. In this sense, it is concluded that in order to develop an accurate and efficient predictive degradation model, the different relevant scales ranging from nano- to macro-sized scales should be considered, and coupling techniques for multiscale modeling have to be advanced. Finally, the paper summarizes the degradation models for different MEA components. It is highlighted that the GDL chemical degradation models that describe damage accumulation are relatively limited. The paper provides a useful reference for the recent developments in the MEA degradation modeling of PEMFCs.