Deformation of PEM fuel cell gas diffusion layers under compressive loading: An analytical approach

• A new mechanistic model has been developed to predict the PEMFCs GDL's behavior under compression.
• Unit cell approach has been utilized to model the GDL's complex microstructure.
• The model takes into account microstructural parameters and properties of the fibrous porous medium.

In the PEM fuel cell stack, the fibrous porous gas diffusion layer (GDL) provides mechanical support for the membrane assembly against the compressive loads imposed by bipolar plates. In this study, a new mechanistic model is developed using fundamental beam theory that can accurately predict the mechanical deflection of GDL under compressive loads. The present analytical model is built on a unit cell approach, which assumes a simplified geometry for the complex and random GDL microstructure. The model includes salient microstructural parameters and properties of the fibrous porous medium including: carbon fiber diameter, fiber elastic modulus, pore size distribution, and porosity. Carbon fiber bending is proved to be the main deformation mechanism at the unit cell level. A comprehensive optical measurement study with statistical analysis is performed to determine the geometrical parameters of the model for a number of commercially available GDL samples. A comparison between the present model and our experimental stress–strain data shows a good agreement for the linear deformation region, where the compressive pressure is higher than 1 MPa.