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The increasing use of intermittent renewable energy sources calls for novel approaches to large-scale energy conversion and storage. Hydrogen can be readily stored and produced from renewable sources using polymer electrolyte membrane water electrolysers (PEMWEs). Mass transport of water and product gas in the liquid-gas diffusion layer (LGDL) is critical for PEMWE performance, particularly at high current densities. In this work, neutron radiography is deployed to measure the spatial distribution of water within three different LGDLs, while X-ray micro-computed tomography (XCT) is used to characterize the microstructure of the LGDL materials. The combination of these two techniques yields valuable insight into water transport within the LGDL. Significant local water heterogeneity is observed and a link between flow-field geometry/location and LGDL mass transport is identified. It is further shown that the pore volume in these LGDLs is significantly under-utilized, pointing the way towards design optimisation of LGDL materials and architectures.

The porous transport layer (PTL) in polymer electrolyte membrane water electrolysers (PEMWEs) has the multiple roles of delivering water to the electro-catalyst, removal of product gas, and acts as a conduit for electronic and thermal transport. They are, thus, a critical component for optimized performance, especially at high current density operation. This study examines the relationship between the microstructure and corresponding electrochemical performance of commonly used titanium sinter PTLs. Four PTLs, with mean pore diameter (MPD) ranging from 16 µm to 90 μm, were characterized ex-situ using scanning electron microscopy and X-ray computed micro-tomography to determine key structural properties. The performance of these PTLs was studied operando using polarization and electrochemical impedance spectroscopy. Results showed that an increase in mean pore size of the PTLs correlates to an increase in the spread and multimodality of the pore size distribution and a reduction in homogeneity of porosity distribution. Electrochemical measurements reveal a strong correlation of mean pore size of the PTLs with performance. Smaller pore PTLs showed lower Ohmic resistance but higher mass transport resistance at high current density of 3.0 A cm-2. A non-monotonic trend of mass transport resistance was observed for different PTLs, which suggests an optimal pore size beyond which the advantageous influence of macroporosity for mass transport is diminished. The results indicate that maximizing contact points between the PTL and the catalyst layer is the overriding factor in determining the overall performance. These results guide PTL design and fabrication of PEMWEs.

Over the last decade, acoustic methods, including acoustic emission (AE) and ultrasonic testing (UT), have been increasingly deployed for process diagnostics and health monitoring of electrochemical power devices, including batteries, fuel cells, and water electrolysers. These techniques are non-invasive, highly sensitive, and low-cost, providing a high level of spatial and temporal resolution and practicality. Their application in electrochemical devices is based on identifying changes in acoustic signals emitted from or propagated through materials as a result of physical, structural, and electrochemical changes within the material. These changes in acoustic signals are then correlated to critical processes and the health status of these devices. This review summarises progress in the use of acoustic methods for the process and health monitoring of major electrochemical energy conversion and storage devices. First, the fundamental principles of AE and UT are introduced, and then the application of these acoustic techniques to electrochemical power devices are discussed. Conclusions and perspectives on some of the key challenges and potential commercial and academic applications of the devices are highlighted. It is expected that, with further developments, acoustic techniques will form a key part of the suite of diagnostic techniques routinely used to monitor electrochemical devices across various processes, including fabrication, post-mortem examination and recycle decision support to aid the deployment of these devices in increasingly demanding applications.

Identification of the state-of-health (SoH) of Li-ion cells is a vital tool to protect operating battery packs against accelerated degradation and failure. This is becoming increasingly important as the energy and power densities demanded by batteries and the economic costs of packs increase. Here, ultrasonic time-of-flight analysis is performed to demonstrate the technique as a tool for the identification of a range of defects and SoH in Li-ion cells. Analysis of large, purpose-built defects across multiple length scales is performed in pouch cells. The technique is then demonstrated to detect a microscale defect in a commercial cell, which is validated by examining the acoustic transmission signal through the cell. The location and scale of the defects are confirmed using X-ray computed tomography, which also provides information pertaining to the layered structure of the cells. The demonstration of this technique as a methodology for obtaining direct, non-destructive, depth-resolved measurements of the condition of electrode layers highlights the potential application of acoustic methods in real-time diagnostics for SoH monitoring and manufacturing processes.