The gas diffusion layer of air electrode was prepared by the rolling method with acetylene black and 60% PTFE emulsion as raw materials.The performance parameters of sintered and non-sintered gas diffusion layer and its effects on the life of air electrode were studied.The pore structure and morphology of gas diffusion layer were studied by mercury intrusion method and SEM.The results showed that the air electrode with sintered gas diffusion layer had longer life compared with the one with non-sintered gas diffusion layer,the 1 000 h life test had no flooded and the electrochemical performance was better.The hydrophobicity and porosity of the electrode material were improved by sintering.The optimal pore structure of the sintered gas diffusion layer was about 70% in porosity and about 70 nm in mean pore diameter.