Two-phase flow in coupled gas diffusion layer and patterned wettability metal foam flow field in PEM fuel cells

Xuecheng Lv, Zhifu Zhou, Wei-Tao Wu, Lei Wei, Linsong Gao, Jizu Lyu, Yang Li, Yunjie Yang, Yubai Li and Yongchen Song

Renewable Energy, 2025, vol. 242, issue C

Abstract: This study reconstructs the 3D structures of the gas diffusion layer (GDL) and metal foam flow field (MFF) in proton exchange membrane fuel cells (PEMFCs) using X-ray computed tomography. The innovation lies in applying the phase-field lattice Boltzmann method (a mesoscopic approach) to simulate two-phase flow in the GDL-MFF coupling region. Results show that, compared to hydrophobic metal foam (HMF), a patterned wettability metal foam (PWMF) with a hydrophilic region contact angle of 5° and a diameter of 0.3 mm improves several performance aspects. These include reducing liquid water coverage at the GDL-MFF interface (below 2 %), enhancing vertical gas convection in the GDL, lowering and stabilizing pressure in the MFF, and achieving a more uniform gas velocity distribution. However, improper PWMF design can slow liquid water transport from the GDL to the MFF, increasing water saturation in the GDL and reducing drainage rates. A contact angle of around 65° in the hydrophilic region of PWMF enhances PEMFC performance, increasing vertical gas convection by 67 % compared to HMF, without reducing liquid water transport. When the diameter of the hydrophilic region exceeds the MFF's average pore size, vertical convection in the GDL improves by 40 %, while maintaining liquid water transport.

Keywords: Proton exchange membrane fuel cell; Water management; Two-phase flow; Gas diffusion layer; Metal foam flow field (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:renene:v:242:y:2025:i:c:s0960148125000813

DOI: 10.1016/j.renene.2025.122419

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