Nickel foams are excellent candidate materials for gas diffusion layers (GDLs) for polymer electrolyte fuel cells (PEFCs) and this is due to their superior structural and transport properties. A highly computationally-efficient framework has been developed to not only estimate the key structural and mass transport properties but also to examine the multi-dimensional uniformity and/or the isotropy of these properties. Specifically, multiple two-dimensional X-ray CT images and/or numerical models have been used to computationally determine the porosity, the tortuosity, the pore size distribution, the ligament thickness, the specific surface area, the gas permeability and the effective diffusivity of a typical nickel foam sample. The results show that, compared to the conventionally used carbon substrate, the nickel foam sample demonstrate a high degree of uniformity and isotropy and that it has superior structural and mass transport properties, thus underpinning its candidacy as a GDL material for PEFCs. All the computationally-estimated properties, which were found to be consistent with the corresponding literature data, have been presented and thoroughly discussed
