Parametric Reconstruction and Pore-Scale Transport Analysis of Microporous Layers in PEM Fuel Cells

The microporous layer (MPL) is a key functional component in proton exchange membrane fuel cells (PEMFCs), and clarifying the quantitative relationship between its microstructure and mass transport properties is essential for improving cell performance. In this study, a three-dimensional MPL model was developed using a stochastic reconstruction method, and, together with a random walk algorithm, was employed to systematically investigate the effects of porosity, carbon sphere radius, maximum overlap ratio, seed ratio, and polytetrafluoroethylene (PTFE) content on permeability, effective diffusivity, and tortuosity. The results reveal that increasing porosity reduces tortuosity from 1.7 to 1.3, while permeability and effective diffusivity increase by factors of approximately 6.5 and 1.8, respectively. As the carbon sphere radius increases, tortuosity decreases from 1.55 to 1.35, accompanied by an increase in permeability from 2 × 10−16 m2 to 20 × 10−16 m2. Moreover, increasing the PTFE content raises permeability from 5 × 10−16 m2 to 22.5 × 10−16 m2, corresponding to an enhancement by a factor of approximately 4.5. The high-accuracy fitting equations obtained from the simulation results provide theoretical guidance for the microstructural design and optimization of MPLs, which can enhance oxygen transport and water management, reduce mass transport losses, and thereby benefit high-power-density operation and the overall efficiency of PEM fuel cells.