Multi-Factor Optimization of Nickel Foam Flow Fields: Insights into Structural and Surface Modifications for...

Area of Science:

• Materials Science
• Electrochemistry
• Energy Conversion

Background:

• Proton exchange membrane fuel cells (PEMFC) are crucial for clean energy.
• Flow field design significantly impacts PEMFC performance and durability.
• Nickel foam is a potential material for flow fields, but its properties require optimization.

Purpose of the Study:

• To investigate the influence of nickel foam physical properties on PEMFC performance.
• To evaluate the effects of compression, pore size, hydrophobicity, and surface treatments.
• To identify optimal parameters for enhanced electrochemical performance, water management, and corrosion resistance.

Main Methods:

• Systematic variation of nickel foam parameters: compression, pore size, hydrophobicity, and anti-corrosion treatments.
• Electrochemical performance testing of PEMFCs with modified nickel foam.
• Analysis of water management and corrosion resistance.

Main Results:

• Moderate compression (67% porosity 85%) maximized power density (0.918 W cm⁻²) and conductivity.
• Excessive compression led to fractures and reduced water management.
• Smaller pore sizes increased concentration losses due to fluid resistance and water retention.
• Hydrophobic treatments improved water removal but increased ohmic losses.
• Graphene coatings provided the best balance of hydrophobicity, corrosion resistance, and conductivity.

Conclusions:

• Nickel foam properties critically affect PEMFC performance and durability.
• Optimal compression and pore size are essential for efficient mass transport and water management.
• Graphene is a promising anti-corrosion coating for enhancing PEMFC longevity.