Impact of Gas Diffusion Layer Compression on Electrochemical Performance in Proton Exchange Membrane Fuel Cells: A Three-Dimensional Lattice Boltzmann Pore-Scale Analysis

Proton exchange membrane fuel cells (PEMFCs) are being pursued for applications in the maritime industry to meet stringent ship emissions regulations. Further basic research is needed to improve the performance of PEMFCs in marine environments. Assembly stress compresses the gas diffusion layer (GDL) beneath the ribs, significantly altering its pore structure and internal transport properties. Accurate evaluation of the PEMFC cathode’s electrochemical performance at the pore scale is critical. This study employs a three-dimensional multicomponent gas transport and electrochemical reaction lattice Boltzmann model to explore the complex interplay between GDL compression and factors such as overpotential, pressure differential, porosity, and porosity gradient on PEMFC performance. The findings indicate that compression accentuates the reduction in oxygen concentration along the flow path and diminishes the minimum current density. Furthermore, compression exacerbates the reduction in current density under varying pressure conditions. Increased local porosity near the catalyst layer (CL) enhances oxygen accessibility and water vapor exclusion, thereby elevating the mean current density. Sensitivity analysis reveals a hierarchy of impact on mean current density, ranked from most to least significant: overpotential, porosity, compression, porosity gradient, and pressure difference. These insights into the multicomponent gas transfer dynamics within compressed GDLs inform strategic structural design enhancements for optimized performance.