One of the bottlenecks hindering the usage of polymer electrolyte membrane fuel cell technology in automotive applications is the highly load-sensitive degradation of the cell components. The cell failure cases reported in the literature show localized cell component degradation, mainly caused by flow-field dependent non-uniform distribution of reactants. The existing methodologies for diagnostics of localized cell failure are either invasive or require sophisticated and expensive apparatus. In this study, with the help of a multiscale simulation framework, a single polymer electrolyte membrane fuel cell (PEMFC) model is exposed to a standardized drive cycle provided by a system model of a fuel cell car. A 2D multiphysics model of the PEMFC is used to investigate catalyst degradation due to spatio-temporal variations in the fuel cell state variables under the highly transient load cycles. A three-step (extraction, oxidation, and dissolution) model of platinum loss in the cathode catalyst layer is used to investigate the cell performance degradation due to the consequent reduction in the electro-chemical active surface area (ECSA). By using a time-upscaling methodology, we present a comparative prediction of cell end-of-life (EOL) under different driving behavior of New European Driving Cycle (NEDC) and Worldwide Harmonized Light Vehicles Test Cycle (WLTC).

This paper presents a study of the carbon support corrosion and mitigation strategies through the use of a pseudo-3D model. This model consists in coupling a 2D model along the channel with another model perpendicular to the flow at the rib/channel scale. Simulations offer a deeper understanding of the corrosion through the analysis of the local conditions. Rib/channel heterogeneities show the higher degradation in the zones facing the anodic rib. These results are validated qualitatively on literature data by analysis of SEM images and carbon dioxide concentration at the cathode outlet. Three mitigation strategies are studied using the model. The first one consists in speeding up the hydrogen filling of the cell. The second strategy involves an external electrical resistance to create a current leak during the startup. Third, a design study of the rib/channel is performed to minimize the cathode degradation. Whatever the mitigation strategy, it consists in reducing either the duration or the magnitude of the high cathode electrode potential.

To address the performance and lifetime limitations of Proton Exchange Membrane Fuel Cells, it is essential to have a comprehensive understanding of the operating heterogeneities at the cell scale, requiring the test of a wide range of operating conditions. To avoid experimental constraints, numerical simulations seem to be the most viable option. Hence, there is a need for time-efficient and accurate cell-scale models. In this intention, previous works led to the development and the experimental calibration of a pseudo-3D model of a full-size cell in a stack. To further reduce the computation time, a new spatially averaged, multi-physics, single-phase, non-isothermal, steady state pseudo-3D model is developed and calibrated with the results of the preceding model. Particularly, it captures the influence of the coolant on temperature and water mappings in the cell. Moreover, a new methodology is proposed to calibrate the electrochemical cell voltage law for new membrane-electrode assemblies. The emulation of the local operation conditions in large active surface area is realized with a small differential cell, avoiding the testing of large single cells or stacks. Subsequently, simulations are conducted to investigate the impact of the coolant temperature gradient, coolant outlet temperature and gas relative humidity.

The heterogeneous nature of the cathode catalyst layer has been a major obstacle toward the comprehension of the mechanisms hindering the PEMFC performance at high current densities. To deconvolute these, an approach coupling multiscale modeling and multiscale electron microscopy characterization—allowing to move from the local to the cathode catalyst layer scale—is adopted. Here, an agglomerate scale model is developed and coupled with a MEA-scale model. Different structures are analyzed and the effects of certain structural parameters (Pt particle size, agglomerate structure and Nafion layer thickness) on the electrode performance are quantified and discussed. Reducing the Pt particle size is found to improve performance in most cases, though the improvement margin is highly dependent on the structure, and to a certain extent, on the particle spatial distribution. It is found that thickening the Nafion film is detrimental for performance only when the porosity is not sufficiently large. Performance gains upon structure rearrangement into an ideal-type structure (Nafion and pore tortuosities minimized to unity) are also quantified. These analyses have unvealed the main mechanism limiting performance when shifting to moderate/high current densities and allowed quantifying and ranking the physical phenomena hampering performance by order of importance.