Investigating the effects of gas diffusion layer substrate thickness on polymer electrolyte membrane fuel cell performance via synchrotron X-ray radiography

Synchrotron X-ray radiography was used to visualize the liquid water accumulation in polymer electrolyte membrane (PEM) fuel cells to compare the impact of carbon substrate thickness on water management. A differential fuel cell with an active area of 0.68 cm2 and rib/channel width of 0.2 mm was custom-made to provide 1-dimensional (1D) conditions over the active area. The fuel cell with the thin substrate (TGP-H-030) outperformed the fuel cell with the thick substrate (TGP-H-060). The fuel cell with the thinner substrate exhibited a higher limiting current density, less liquid water in the microporous layer (MPL)-substrate transition region, and reduced oxygen transport resistance measured through electrochemical impedance spectroscopy (EIS). The compression behaviour of each GDL was also investigated through two consecutive fuel cell assemblies. The pressure in the second assembly was lower than that for the initial assemblies for both GDLs, and this significant change in assembly pressure was more pronounced for the thinner GDL (TGP-H-030). The resulting interfacial contact between the catalyst layer and the GDL was degraded, which manifested in the microscale displacement of fuel cell materials during operation (detected as a negative liquid water thickness). While the thinner GDL provided superior performance, the long term effects of material deformation may exacerbate a heterogeneous distribution of liquid water that could also impact the performance.