The use of perforated metal sheets as engineered gas diffusion layers (GDL) in proton exchange membrane (PEM) fuel cells was investigated. The effect of different thicknesses, perforation diameter, and in-plane diffusion capabilities were analyzed along with freestanding microporous layers in order to improve gas and water transport. Although these structured GDLs are in an early stage of development, they provide baseline performance at lower current densities, and may already have potential for some specific applications. In addition, the design, manufacturing, and modeling processes with predictive capability can be improved due to their simplified nature.The two materials used the most as gas diffusion layers (GDL) in the proton exchange membrane fuel cell (PEMFC) industry are carbon fiber papers (CFP) and carbon cloths (CC). 1 However, they have a number of drawbacks, particularly with respect to their design and model complexity. One of the main issues with the CFP/CC used as GDLs is the non-controlled variation in porosity (and other localized properties) since the porosity characteristics between CFP are not always repeatable. 2 Many of the water management and mass transport issues with GDLs could be improved considerably if the GDLs could be carefully tailored to specific fuel cell applications.One approach to the design of these engineered GDLs is through the use of non-porous conductive materials that are perforated based on a detailed design. Research groups from Ballard Power Systems and Graftech Inc. have presented designs of engineered GDLs based on graphitic foils. 3, 4 A number of different designs (e.g., geometry, cross-sectional shape, and hole density) were also proposed. Unfortunately, to the best of our knowledge, there are limited published results from Graftech but none from Ballard that show complete studies of how these perforated graphitic foils perform inside a fuel cell. Other groups have also proposed other non-porous materials as engineered GDLs. 5, 6 None of these studies attempted to understand in detail how the proposed GDLs affected fuel cell performance.Another approach to develop engineered GDLs is through the use of perforations and grooves in CFPs and the weave design in CCs. Based on the earlier work of Wilkinson et al.,7,8 the main idea behind the modification of porous CFPs with perforations is to improve liquid water transport at specific locations of the GDL. More recently, several researchers have shown an improvement in fuel cell performance at different operating conditions by perforating and/or making grooves to conventional CFPs. [9][10][11][12][13][14] In this study, in-situ experiments of perforated stainless steel sheets as GDLs were performed to study the effects of different engineered sheet designs on the performance and transport characteristics inside a PEMFC.
ExperimentalFor all the measurements, a single cell fuel cell with an active area of 49 cm 2 was used. The perforated sheets (PS) were made out of stainless 316L steel sheets and were perforated by V...