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Recently, highly porous metal foams have been used to replace the traditional open-flow channels to improve gas transport and distribution in the cells. Deformation of flow plate, gas diffusion layer (GDL), and metal foam may occur during assembling. When the cell size is small, the deformation may not be significant. For large area cells, the deformation may become significant to affect the cell performance. In this study, an assembling device that is capable of applying uniform clamping force is built to facilitate fuel cell assembling and alleviate the deformation. A compressing plate that is the same size of the active area is used to apply uniform clamping force before surrounding bolts are fastened. Therefore, bending of the flow plate and deformation of GDL and metal foam can be minimized. Effects of the clamping force on the microstructures of GDL and metal foam, various resistances, pressure drops, and cell performance are investigated. Distribution of the contact pressure between metal foam and GDL is measured by using pressure sensitive films. Field-emission scanning electron microscope is used to observe the microstructures. Electrochemical impedance spectroscopy analysis is used measure resistances. The fuel cell performance is measured by using a fuel cell test system. For the cell design used in this study, the optimum clamping force is found to be 200 kgf. Using this optimum clamping force, the cell performance can be enhanced by 50%, as compared with that of the cell assembled without using clamping plates. With appropriate clamping force, the compression force distribution across the entire cell area can approach uniform. This enables uniform flow distribution and reduces mass transfer resistance. Good contact between GDL and metal foam also lowers the interface resistance. All these factors contribute to the enhanced cell performance.

Functional nanostructures with abundant exposed active sites and facile charge transport through conductive scaffolds to active sites are pivotal for developing an advanced and efficient electrocatalyst for water splitting. In the present study, by coating ∼3 nm MoS x on nitrogen-doped graphene (NG) pre-engrafted on a flexible carbon cloth (MNG) as a model system, an extremely low Tafel slope of 39.6 mV dec–1 with cyclic stability up to 5000 cycles is obtained. The specific fraction of N on the NG framework is also analyzed by X-ray photoelectron spectroscopy and X-ray absorption near edge spectroscopy with synchrotron radiation light sources, and it is found that the MoS x particles are selectively positioned on the specific graphitic N sites, forming the unique Mo–N–C bonding state. This Mo–N–C bonding is founded to facilitate highly effective charge transfer directly to the active sulfur sites on the edges of MoS x , leading to a highly improved hydrogen evolution reaction (HER) with excellent stability (95% retention @ 5000 cycles). The functional anchoring of MoS x by such bonding prevents particle aggregation, which plays a significant role in maintaining the stability and activity of the catalyst. Furthermore, it has been revealed that MNG samples with adequately high amounts of both pyridinic and graphitic N result in the best HER performance. This work helps in understanding the mechanisms and bonding interactions within various catalysts and the scaffold electrode.

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