A critical review on gas diffusion micro and macroporous layers degradations for improved membrane fuel cell durability

Formerly considered as a secondary component of fuel cell, gas diffusion layers (GDLs) have been shown to have a key role in gas transport to the catalyst layers and in water management: in particular, the microporous layer (MPL) deposited on the diffusion substrate has an active part in water distribution in the membrane electrode assembly and in its efficient removal from the cell. In addition to its perfect design for the targeted application and in combination with the macroporous substrate (MPS), the MPL structure and physicochemical properties have to contribute to the cell durability, which is still considered as insufficient for larger, massive commercialisation of this energy conversion system. The paper is aimed at reviewing the main knowledge gained on the role of the MPL on GDL operation and durability, with investigation of degradation phenomena of both MPL and MPS, together with the role played by the MPL in mitigating the occurrence of degradation phenomena that can occur in the whole fuel cell. In addition to the reviewing purpose, original data on ex-situ degradation of GDL are presented. •Physical phenomena related to MPL on GDL within the fuel cell, are analysed.•The role of MPL in fuel cell performance and durability has been reviewed.•Mechanical and physicochemical degradation phenomena are discussed.•Promising routes for more efficient MPL and GDL are given.