Catalyst layer modeling can be a useful tool for fuel cell design. By comparing numerical results to experimental results, numerical models can provide a better understanding of the physical processes occurring within the fuel cell catalyst layer. This can lead to design optimization and cost reduction. The purpose of this research was to compare, for the first time, a direct numerical simulation (DNS) model for the cathode catalyst layer of a PEM fuel cell to a newly developed experimental technique that measures the ionic potential through the length of the catalyst layer. A new design for a microstructured electrode scaffold (MES) is proposed and implemented. It was found that there is a 25%-27% difference between the model and the experimental measurements. Case studies were also performed with the DNS to compare the effects of different operating conditions, specifically temperature and relative humidity, and different reconstructed microstructures. Suggested operating parameters are proposed for the best comparison between numerical and experimental results. Recommendations for microstructure reconstruction, MES construction and design, and potential measurement techniques are also given. / Master of Science

Research and prototyping of a fuel cell stack system for micro aerial vehicles (MAVs) was conducted by Virginia Tech in collaboration with Luna Innovations, Inc, in an effort to replace the lithium battery technology currently powering these devices. Investigation of planar proton exchange membrane (PEM) and direct methanol (DM) fuel cells has shown that these sources of power are viable alternatives to batteries for electronics, computers, and automobiles. However, recent investigation about the use of microtubular fuel cells (MTFCs) suggests that, due to their geometry and active surface areas, they may be more effective as a power source where size is an issue. This research focuses on hydrogen MTFCs and how their size and construction within a stack affects the power output supplied to a MAV, a small unmanned aircraft used by the military for reconnaissance and other purposes. In order to conduct this research effectively, a prototype of a fuel cell stack was constructed given the best cell characteristics investigated, and the overall power generation system to be implemented within the MAV was modeled using a computer simulation program. The results from computer modeling indicate that the MTFC stack system and its balance of system components can eliminate the need for any batteries in the MAV while effectively supplying the power necessary for its operation. The results from the model indicate that a hydrogen storage tank, given that it uses sodium borohydride (NaBH4), can fit inside the fuselage volume of the baseline MAV considered. Results from the computer model also indicate that between 30 and 60 MTFCs are needed to power a MAV for a mission time of one hour to ninety minutes, depending on the operating conditions. In addition, the testing conducted on the MTFCs for the stack prototype has shown power densities of 1.0, an improvement of three orders of magnitude compared to the initial MTFCs fabricated for this project. Thanks to the results of MTFC testing paired with computer modeling and prototype fabrication, a MTFC stack system may be possible for implementation within an MAV in the foreseeable future. / Master of Science

Os eletrocatalisadores Pt/C e Pt-Terras Raras/C (terras raras = La, Ce, Pr, Nd, Sm, Tb, Dy, Ho, Er, Tm, and Lu) foram preparados (20% em massa e razão atômica Pt-TR de 50:50) pelo método de redução por álcool, usando H2PtCl6.6H2O (Aldrich) e Terras Raras Cl3.xH2O (Aldrich) como fonte de metais, etileno glicol como solvente e agente redutor e, o carbono Vulcan XC72, como suporte. Os catalisadores foram caracterizados por espectroscopia de energia dispersiva de raios X (EDX), análises de difração de raios X (DRX) e microscopia de transmissão eletrônica (TEM). As análises por EDX mostraram que as razões atômicas dos diferentes eletrocatalisadores Pt-TR/C preparados foram similares às composições nominais de partida. Em todos os difratogramas, observa-se um pico largo em aproximadamente 2 = 25o o qual foi associado ao suporte de carbono Vulcan XC72 e quatro outros picos de difração em aproximadamente 2 = 40o, 47o, 67o e 82o os quais são associados aos planos (111), (200), (220) e (311), respectivamente, da estrutura cúbica de face centrada (CFC) de platina e suas ligas. Para os eletrocatalisadores Pt-TR/C também foram observadas fases nos difratogramas de raios X referentes aos óxidos de terras raras. Foram preparados eletrocatalisadores Pt-La/C com diferentes razões atômicas. Micrografias de transmissão eletrônica apresentaram uma razoável distribuição das partículas de Pt no suporte de carbono com algumas aglomerações, o que está de acordo com os resultados de difração de raios X. O desempenho para a oxidação de CO, metanol e etanol foi investigada através de voltametria cíclica, cronoamperometria e espectroscopia no infravermelho com transformada de Fourier. A atividade eletrocatalítica dos eletrocatalisadores Pt-TR/C, em especial PtLa/C, foram maiores que do Pt/C. A investigação por espectroscopia no infravermelho com transformada de Fourier para a oxidação de etanol com os eletrocatalisadores PtLa/C mostrou que o acetoaldeído e o ácido acético foram os principais produtos formados. O eletrocatalisador PtLa/C (30:70) apresentou melhores resultados para a reação de redução de oxigênio, oxidação de metanol e etanol, e a temperaturas superiores a 30°C para oxidação de monóxido de carbono. / PREPARATION AND CHARACTERIZATION OF PT-RARE EARTH/C ELECTROCATALYSTS FOR PEM FUEL CELLS

Os eletrocatalisadores Pt/C e Pt-Terras Raras/C (terras raras = La, Ce, Pr, Nd, Sm, Tb, Dy, Ho, Er, Tm, and Lu) foram preparados (20% em massa e razão atômica Pt-TR de 50:50) pelo método de redução por álcool, usando H2PtCl6.6H2O (Aldrich) e Terras Raras Cl3.xH2O (Aldrich) como fonte de metais, etileno glicol como solvente e agente redutor e, o carbono Vulcan XC72, como suporte. Os catalisadores foram caracterizados por espectroscopia de energia dispersiva de raios X (EDX), análises de difração de raios X (DRX) e microscopia de transmissão eletrônica (TEM). As análises por EDX mostraram que as razões atômicas dos diferentes eletrocatalisadores Pt-TR/C preparados foram similares às composições nominais de partida. Em todos os difratogramas, observa-se um pico largo em aproximadamente 2 = 25o o qual foi associado ao suporte de carbono Vulcan XC72 e quatro outros picos de difração em aproximadamente 2 = 40o, 47o, 67o e 82o os quais são associados aos planos (111), (200), (220) e (311), respectivamente, da estrutura cúbica de face centrada (CFC) de platina e suas ligas. Para os eletrocatalisadores Pt-TR/C também foram observadas fases nos difratogramas de raios X referentes aos óxidos de terras raras. Foram preparados eletrocatalisadores Pt-La/C com diferentes razões atômicas. Micrografias de transmissão eletrônica apresentaram uma razoável distribuição das partículas de Pt no suporte de carbono com algumas aglomerações, o que está de acordo com os resultados de difração de raios X. O desempenho para a oxidação de CO, metanol e etanol foi investigada através de voltametria cíclica, cronoamperometria e espectroscopia no infravermelho com transformada de Fourier. A atividade eletrocatalítica dos eletrocatalisadores Pt-TR/C, em especial PtLa/C, foram maiores que do Pt/C. A investigação por espectroscopia no infravermelho com transformada de Fourier para a oxidação de etanol com os eletrocatalisadores PtLa/C mostrou que o acetoaldeído e o ácido acético foram os principais produtos formados. O eletrocatalisador PtLa/C (30:70) apresentou melhores resultados para a reação de redução de oxigênio, oxidação de metanol e etanol, e a temperaturas superiores a 30°C para oxidação de monóxido de carbono. / PREPARATION AND CHARACTERIZATION OF PT-RARE EARTH/C ELECTROCATALYSTS FOR PEM FUEL CELLS

Fuel cells are electricity generators which convert chemical energy of hydrogen directly to electricity by means of electrochemical oxidation and reduction reactions. A single proton exchange membrane (PEM) fuel cell can only generate electricity with a potential between 0.5V and 1V. The useful potential can be achieved by stacking cells in series to form a PEM fuel cell stack. There is a potential to utilize 100W class fuel cells. Fuelling is the major problem of the portable fuel cells. The aim of this thesis is to design and manufacture a PEM fuel cell stack which can be used for portable applications. The PEM fuel cell stack is planned to be incorporated to a NaBH4 hydrolysis reactor for H2 supply. Within the scope of this thesis a new coating technique called &ldquo / ultrasonic spray coating technique&rdquo / is developed for membrane electrode assembly (MEA) manufacturing. New metal and graphite bipolar plates are designed and manufactured by CNC technique. A fuel cell controller hardware is developed for fuel supply and system control. The power densities reached with the new method are 0.53, 0.74, 0.77, and 0.88 W/cm2 for 20%, 40%, 50%, 70% Pt/C catalyst by keeping 0.4mg Pt/cm2 platinum loading constant, respectively. The power density increase is 267% compared to &ldquo / spraying of catalyst ink with air pressure atomizing spray gun&rdquo / . All parts of the PEM fuel cell stack designed were produced, assembled, and tested. The current density reached is 12.9A at 12 V stack potential and the corresponding electrical power of the stack is 155W.

A nickel alloy with high chrome and molybdenum content was found to form a highly resistive and passive oxide layer. The donor density and mobility of ions in the oxide layer has been determined as a function of the electrical potential when alkaline water layers are on the alloy surface in order to account for the relative inertness of the nickel alloy in corrosive environments.

This thesis presents a compendium of work related to performance analyses of a proton electrolyte membrane (PEM) fuel cell with two novel design configurations. The finite element based numerical analysis has been carried out to solve the numerical transport models involved in a PEM fuel cell coupled with the flow in a porous medium, charge balance, electrochemical kinetics and membrane water content. The scope of this research work focuses on improving the performance of the PEM fuel cell by optimizing the thermo-fluid properties of the reactant species instead of analysing the complex electro-chemical interactions. Two new design configurations have been numerically analyzed; in the first design approach, a perforated-type gas flow distributor is used instead of a conventional gas flow distributor such as a serpentine, straight or spiral shape; the second design approach examines the effect of reactant flow pulsation on the PEM fuel cell performance. Results obtained from the numerical analyses were also compared with the experimental data and a good agreement was found. Performance of the PEM fuel cell with a perforated-type gas distributor was analyzed at different operating and geometric conditions to explore the merits of this new design configuration. Two-dimensional numerical analyses were carried out to analyze the effect of varying the different operating parameters; threedimensional numerical analyses were carried out to study the variation of different geometric parameters on overall performance of the new design configuration of the PEM fuel cell. The effects of the reactant flow pulsation on the performance of PEM fuel cell were analyzed using a two-dimensional numerical approach where both active and passive design configurations were numerically simulated to generate the pulsations in the reactant flow. The results showed a considerable increase in overall performance of the PEM fuel cell by introducing pulsations in the flow.

Philosophiae Doctor - PhD / Fuel cells are long term solution for global energy needs. In current fuel cell technologies, Proton Exchange Membrane (PEM) fuel cells are known for quick start-up and ease of operation compared to other types of fuel cells. Operating PEM fuel cells at high temperature show promising applications for stationary combined heat and power application (CHP). The high operating temperature up to 160°C allows waste heat to be recovered for co-generation or tri-generation purposes. The commercially available PEM fuel cells operating at 160⁰C can tolerate up to 3% CO without significant loss of performance, making HT-PEM fuel cell viable choice when reformate is used. In reality these advantages convert to very little balance-of-plant compared to Nafion® based fuel cells operating at 60°C. However, there are some problems that prevent high temperature fuel cells from large scale commercialization. The cathode is said to have sluggish reaction kinetics and high cell potentials and operating temperature during fuel cell start-up may cause severe degradation. The formation of liquid water during the shut-down can cause the phosphoric acid to leach from the cell during operation. Efforts are being made to reduce the cost and increase the durability of fuel cell components (such as catalyst and membrane) at high temperatures. Apart from degradation issues, the problems are related to cost and performance. The performance of the PEM fuel cells depends on a lot of factors such as fuel cell design and assembly, operating conditions and the flow field design used on the cathode and anode plates. The flow field geometry is one important factor influencing the performance of fuel cells. The flow fields have significant effect on pressure and flow distribution inside the fuel cell. A homogeneous distribution of the reactant gases over the active catalyst surface leads to improved electrochemical reactions and thus enhances the performance of the fuel cell. So, the design of flow fields is one of the important issues for performance improvement of PEM fuel cell in terms of power density and efficiency. There are different types of flow fields available for PEM fuel cells such as serpentine, pin, interdigitated and straight flow fields but the most obvious choice is multiple serpentine. The same can be used for high temperature PEM fuel cell (HT-PEMFC) application with ease because of absence of liquid water during the high temperature operation and no need for complex water management.

Fuel cells are predicted to be the power delivery devices of the future. They have many advantages such as the wide fuel selection, high energy density, high efficiency and an inherent safety which explains the immense interest in this power source. The need for advanced designs has been limited by the lack of understanding of the transport processes inside the fuel cell stack. The reactant gases undergo many processes in a fuel cell that cannot be observed. Some of these processes include convective and diffusional mass transport through various types of materials, phase change and chemical reaction. In order to optimize these variables, an accurate mathematical model can provide a valuable tool to gain insight into the processes that are occurring. The goal of this dissertation is to develop a mathematical model for polymer electrolyte-based fuel cells to help contribute to a better understanding of fuel cell mass, heat and charge transport phenomena, to ultimately design more efficient fuel cells. The model is a two-phase, transient mathematical model created with MATLAB. The model was created by using each fuel cell layer as a control volume. In addition, each fuel cell layer was further divided into the number of nodes that the user inputs into the model. Transient heat and mass transfer equations were created for each node. The catalyst layers were modeled using porous electrode equations and the Butler-Volmer equation. The membrane model used Fick's law of diffusion and a set of empirical relations for water uptake and conductivity. Additional work performed for this dissertation includes a mathematical model for predicting bolt torque, and the design and fabrication of four fuel cell stacks ranging in size from macro to micro scale for model validation. The work performed in this dissertation will help improve the designs of polymer electrolyte fuel cells, and other polymer membrane-based fuel cells (such as direct methanol fuel cells) in the future.

Excessive water formation inside the polymer electrolyte membrane (PEM) fuel cell’s structures leads to the flooding of the cathode gas diffusion layer (GDL) and cathode gas flow channels. This results in a negative impact on water management and the overall cell performance. Liquid water generated in the cathode catalyst layer and the water moved from anode to cathode side due to electro-osmotic drag transport through the GDL to reach the gas flow field channels, where it is removed by air cathode gas stream. Due to high and uniform capillary force distribution effect of the pores through the GDL plane and surface tension between the water droplets and gas flow field channels surfaces, liquid water tends to block/fill the pores of the GDL and stick to the surface of the GDL and gas flow channels. Therefore, it is difficult to remove the trapped water in GDL structure which can lead to flood of the PEM fuel cell. The GDL surfaces are commonly treated uniformly with a hydrophobic material in order to overcome the flooding phenomena inside PEM fuel cell. Despite the importance impact of the surface wettability of both channel and GDL surface characteristics especially for the cathode side on the water management, few experimental studies have been conducted to investigate the effect of the two-phase flow in cathode gas flow channel and their crucial role. The work presented in this thesis covers contributions that provide insight, not only into the investigation of the effects of hydrophobic cathode GDL and cathode gas flow channels, on water removal, two phase flow inside the channel, and on PEM fuel cell performance, but also the superhydrophobic and superhydrophilic GDLs and gas flow channels effects. Further, the effects of a novel GDL designs with sandwich and gradient wettability with driving capillary force through GDL plane have been investigated. Two-phase flow especially in the cathode gas flow field channels of PEM fuel cell has a crucial role on water removal. Hence, in this research, ex-situ investigations of the effects of channels with different surface wettability; superhydrophobic, hydrophobic, slightly hydrophobic, and superhydrophilic on the two-phase flow characteristics have been tested and visualized at room temperature. Pressure drop measurements and two-phase flow visualization have been carried out using high speed camera. The effect of the various coating materials on graphite and GDL surface morphology, roughness, static contact angle (θ), and sliding contact angle (α) have been investigated using scanning electron microscopy (SEM), Profilometry, and sessile drop technique, respectively. It has been observed that the two-phase flow resistance is considerably affected by surface wettability of the channels. Further, the overall cell performance can be improved by superhydrophobic gas flow channels mainly at high current density over slightly hydrophobic and superhydrophilic cases tested. In addition, sandwich wettability GDL has been coated with a silica particle/ Polydimethylsiloxane (PDMS) composite. The porometric characteristics have been studied using, method of standard porosimetry (MSP). It has been found that sandwich wettability GDL has superhydrophobic surfaces with (θ = 162±2°), (α = 5±1°), and the internal pores are hydrophilic, while the mean pore radius is 7.1μm. This shows a low resistance to gas transport. On the other hand, performance testing indicates that (PEM) fuel cell equipped with sandwich wettability GDL results in the best performance compared to those with raw (non-coated) (slightly hydrophobic), PTFE coated (commercial with micro-porous layer (MPL)) (superhydrophobic), and silica coated (superhydrophilic) GDL. The wettability gradient has been introduced through plane of the one side hydrophobic GDL by coating one side of non-coated GDL with 15 wt. % of PTFE solution; however, the other side remains uncoated. The effects of wettability gradient on the water removal rate, droplet dynamics, and PEM fuel cell performance have been covered in this thesis. Water removal rate is determined using a 20 ml syringe barrel, wherein a 13 mm diameter GDL token is fixed on the barrel opening. The droplets penetrating through the GDL are visualized via a high speed camera to study the droplets’ dynamic characteristics. The GDL wettability gradient has a significant impact on water removal rate, droplets’ dynamic characteristics, and consequently enhances the overall PEM fuel cell performance.