Open pore cellular foams (OPCF) have attracted substantial attention for use as flow-field plates in proton exchange membrane fuel cells due to their potential to enhance the performance [1]. Moreover, they could help to mitigate membrane degradation due to the hygrothermal stresses, which are generally observed in fuel cells that use bipolar plates with the channel-rib structure [2].

In order to optimize the structure and operating conditions of OPCF for use in proton exchange membrane fuel cells, we performed coupled numerical and experimental studies. The numerical studies used a 2-D model that solved mass and momentum conservation and species transport, and coupled them to an electrochemical model in the catalyst layers for the source terms. Parametric studies indicated that some OPCF’s properties like thickness, porosity and pore diameter highly impact the global performance of the cell, and that the optimal properties could considerably be influenced by current density, humidity, and cell dimensions.

The results allowed for the design of optimized OPCF in different operating conditions, which were tested in fuel cells. It was observed that the optimized OPCF were very efficient in enhancing the performance of the cells at high currents, where mass transport limitations are generally observed. Promising solutions for heat and water management were explored.

[1] Ahrae Jo and Hyunchul Ju, Numerical study on applicability of metal foam as flow distributor in polymer electrolyte fuel cells. Int. J. Hydrogen Energy 43, 2018.

[2] Fredy Nandjou et al., Impact of heat and water management on proton exchange membrane fuel cells degradation in automotive application, J. Power Sources 326, 2016.