Proton exchange membrane water electrolysis (PEMWE) is a promising solution for the conversion and storage of fluctuating renewable energy sources. Although tremendously efficient materials have been developed, commercial PEMWE products still cannot fulfill industrial demands regarding efficiency and stability. In this work, we demonstrate that the stress distribution, a purely mechanical parameter in electrolyzer assembly, plays a critical role in overall efficiency and stability. The conventional cell structure, which usually adopts a serpentine flow channel (S-FC) to deliver and distribute reactants and products, resulted in highly uneven stress distribution. Consequently, the anode catalyst layer (ACL) under the high stress region was severely deformed, whereas the low stress region was not as active due to poor electrical contact. To address these issues, we proposed a Ti mesh flow channel (TM-FC) with gradient pores to reduce the stress inhomogeneity. Consequently, the ACL with TM-FC exhibited 27 mV lower voltage initially and an 8-fold reduction in voltage degradation rate compared to that with S-FC at 2.0 A/cm². Additionally, the applicability of the TM-FC was demonstrated in cross-scale electrolyzers up to 100 kW, showing a voltage increase of only 20 mV (accounting for less than 2% of overall voltage) after three orders of magnitude scaleup.

The objective of this study was to investigate the performance of pipelines repaired with carbon-fibre-reinforced polymer (CFRP) under external pressure. The repaired pipeline experienced defects in terms of thinning of its local inner wall. The three-dimensional finite element method was used to analyse the collapse pressure of repaired pipes with internal corrosion defects. The traction–separation law and interlaminar damage criterion were applied to simulate the collapse process of repaired pipes. The results show that the collapse pressure of the composite-repaired pipe increased and the CFRP significantly reduced the strain in the defect region. It was observed that the ovality of the corrosion defect region was reduced and that the repair effectiveness mainly depended on the length, thickness, and interlayer cohesion.

The current density distribution over the catalyst layer was detected using a developed RuO₂ probe.