Proton exchange membrane fuel cells: advances in materials development, performance optimization, and future outlook

Proton exchange membrane fuel cells (PEMFCs) are emerging as a promising energy conversion technology for sustainable power generation, offering high efficiency, low emissions, and adaptability to various applications, including transportation, stationary power systems, and portable electronics. This review critically examines the recent advancements in PEMFC components, including proton exchange membranes, catalyst layers, gas diffusion layers, and bipolar plates, focusing on material innovations, performance enhancements, and durability improvements. The study highlights recent developments in membrane technologies, such as perfluorosulfonic acid membranes, alternative hydrocarbon-based polymers, and composite structures, aimed at enhancing proton conductivity, mechanical stability, and hydration management under varying operational conditions. Furthermore, advancements in catalyst materials, including platinum group metal alloys, non-precious metal catalysts, and atomically dispersed catalysts, are discussed concerning their electrochemical activity, cost-effectiveness, and stability under fuel cell operating conditions. The impact of gas diffusion layer architecture, microporous layer optimization, and novel flow field designs on mass transport characteristics and water management is critically discussed. Additionally, this study examines key challenges, including high production costs, inadequate infrastructure, and technical barriers related to water management, membrane durability, and catalyst efficiency. Recent modeling and simulation approaches for optimizing fuel cell performance, including multi-physics simulations and machine-learning-assisted diagnostics, are also examined. Finally, future research directions are outlined, emphasizing the need for innovative materials, scalable manufacturing techniques, and integrated hydrogen economy strategies to accelerate the global deployment of PEMFC technology to meet net-zero emissions targets by 2050.