in Wiley InterScience (www.interscience.wiley.com).The process of flooding has been examined with a single-channel fuel cell that permits direct observation of liquid water motion and local current density. As product water flows through the largest pores in the hydrophobic GDL, drops detach from the surface, aggregate, and form slugs. Flooding in polymer electrolyte membrane (PEM) fuel cells occurs when liquid water slugs accumulate in the gas flow channel, inhibiting reactant transport. Because of the importance of gravity, we observe different characteristics with different orientations of the flow channels. Liquid water may fall away from the GDL and be pushed out with minimal effect on the local current density, accumulate on the GDL surface and cause local fluctuations, or become a pulsating flow of liquid slugs and cause periodic oscillations. We show that flooding in PEM fuel cells is gravity-dependent and the local current densities depend on dynamics of liquid slugs moving through the flow channels. 2008 American Institute of Chemical Engineers AIChE J, 54: [1313][1314][1315][1316][1317][1318][1319][1320][1321][1322][1323][1324][1325][1326][1327][1328][1329][1330][1331][1332] 2008 Keywords: multi-phase flow, fuel cells, porous media, transport
IntroductionPerhaps the greatest challenge facing fuel cells is the difficulty in maintaining stable operation and control due to flooding by liquid water. The build up of water produced at the membrane/cathode interface is known to limit the current output from PEM fuel cells. To describe the effects of flooding, several models have been proposed. [1][2][3][4][5][6] Most of these hypothesize that liquid water condenses in the pores of the gas diffusion layer (GDL) creating a mass transfer resistance for oxygen to get to the membrane/electrode interface as illustrated in Figure 1.Our group recently examined water permeation through the GDL and obtained results that contradicted the previous hypotheses about liquid flooding. 7 The GDL is a woven cloth or paper of carbon fibers that is usually treated with Teflon 1 to increase its hydrophobicity. We showed that water does not enter the GDL until a sufficient hydraulic pressure is applied to overcome the repulsive surface energy. The largest pores in the GDL are the first to permit water penetration, and once water penetrates the pores it can freely drain. Our results suggested a two-highway system for liquid and gas transport through the GDL, as illustrated in Figure 2. Liquid is driven by a hydraulic pressure from the membrane/cathode interface through the largest pores while gas moves from the gas flow channel to the membrane/cathode interface through smaller, but more plentiful, pores. Results that support these conclusions have also been reported using florescence microscopy to view the ex-situ transport of water through carbon paper. 8 Recently, water intrusion has been used to determine the capillary pressure vs. liquid saturation curves for different GDL materials 9,10 , providing pore volume distributions...