Suggested Citation:
Wu, Siyuan, Chasen Tongsh, Qing Du, Jae Wan Park, Kui Jiao (2025)

A Comprehensive Experimental Investigation of the Operating Conditions on the Performance of Proton Exchange Membrane Fuel Cell Using Metal Foam as Cathode Flow Field

Metal foam flow fields have emerged as a promising alternative to conventional channel-rib designs in proton exchange membrane fuel cells (PEMFCs), offering enhanced performance. This study comprehensively investigates the effects of operating conditions on PEMFCs using nickel foam as the cathode flow field. Results demonstrate that back pressure enhances reactant concentration and membrane hydration at low current densities but increases flooding risk at higher current densities, with limited benefits beyond 100 kPa. Operating temperature significantly influences performance, with 70℃ being optimal, balancing improved electrochemical reaction kinetics and membrane dehydration. Higher intake flow rates enhance water expulsion at high current densities but result in substantial pumping losses, with a 100% increase in flow rate yielding only a 4.7% performance gain but a 604% rise in pumping loss and a 580% rise in pumping loss rate. Optimal performance is achieved at 80% relative humidity of cathode intake gas, reducing both ohmic and activation losses. The PEMFCs use metal foam flow field can to some content achieve self-humidifying operation under proper operating condition control strategy. This work underscores the critical balance among operating conditions in optimizing PEMFCs performance, offering insights for future fuel cell design and operation.