Effect of compression on pore size distribution and porosity of PEM fuel cell catalyst layers

In this study, effects of compression (up to 5 MPa) on pore size distribution (PSD) and porosity of catalyst layers (CL) are investigated using a developed model for deformation of CL under compression. The model is based on effective medium theory and uses a representative geometry (unit cell) to simplify the complex and random porous structure of CL. In this model, different sizes are found for unit cells which are based on CL PSD measurement; this means that unit cell size has distribution since PSD is used as an input to the model. The model has been validated with experimental data in our previous publications. Effect of compression on four different CL samples is studied using the developed model and change of pore diameter is found as function of compression. The change of pore size is different for each sample and dependents on CL initial porosity, PSD, and ink properties. PSD and porosity, which are the indications of microstructure of CL, are found after compression up to 5 MPa. Larger pores show the most change, which causes the void volume percentage of smaller pores to increase, even though the number of pores remain the same. It is also found that the diameter of secondary pores can be decreased by up to 50% depending on CL microstructure, which is significant. •Porosity of CL decreases non-linearly with compressive load (11–17%).•Reduction of larger pores under compression is more significant than smaller ones.•CL pore diameter decreases between 20 and 50% under 5 MPa pressure.•PSD has a shift toward smaller pores due to a significant decrease in larger pores.•Volume percentage of smaller pores increases under compression.