X-ray tomography and modelling study on the mechanical behaviour and performance of metal foam flow-fields for polymer electrolyte fuel cells

Porous metal foams have been used as alternative flow-fields in proton exchange membrane fuel cells (PEMFCs), exhibiting improved performance compared to conventional ‘land and channel’ designs. In the current work, the mechanical behaviour of PEMFCs using metal foam flow-fields is investigated across different length scales using a combination of electrochemical testing, X-ray computed tomography (CT), compression tests, and finite element analysis (FEA) numerical modelling. Fuel cell peak power was seen to improve by 42% when foam compression was increased from 20% to 70% due to a reduction in the interfacial contact resistance between the foam and GDL. X-ray CT scans at varying compression levels reveal high levels of interaction between the metal foam and gas diffusion layer (GDL), with foam ligaments penetrating over 50% of the GDL thickness under 25% cell compression. The interfacial contact area between the foam and GDL were seen to be 10 times higher than between the foam and a stainless-steel plate. Modelling results demonstrate highly uniform contact pressure distribution across the cell due to plastic deformation of the foam. The effect of stack over-tightening and operating conditions are investigated, demonstrating only small changes in load distribution when paired with a suitable sealing gasket material

Characterisation of the diffusion properties of metal foam hybrid flow-fields for fuel cells using optical flow visualisation and x-ray computed tomography

The flow distribution behaviour of open-cell metallic foam fuel cell flow-fields are evaluated using ex-situ optical analysis and X-ray computed tomography (X-ray CT). Five different manifold designs are evaluated and flow distribution and pressure drop quantitatively evaluated with reference to applications in polymer exchange membrane fuel cells (PEMFC) and heat exchangers. A ‘hybrid’ foam flow-field is presented consisting of flow channels pressed into the foam to promote flow distribution and reduce pressure drop. Cross- and through-channel pressure drop measurements are conducted, along with X-ray CT analysis. Results using dyed water show that metallic foams provide excellent fluid distribution across the fuel cell flow-field, closely following the theoretical filling rate. The time for dye to cover 80% of the flow-field area was 61% faster with a foam flow-field then with no flow-field present. Pressure drop was seen to reduce with increasing foam inlet area to levels comparable to multi-serpentine flow-fields. The introduction of flow channels in the foam can further reduce pressure drop and provide more even filling of the foam, at the expense of increased residence time