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Title: Additive manufacturing of liquid/gas diffusion layers for low-cost and high-efficiency hydrogen production

The electron beam melting (EBM) additive manufacturing technology was used to fabricate titanium liquid/gas diffusion media with high-corrosion resistances and well-controllable multifunctional parameters, including two-phase transport and excellent electric/thermal conductivities, has been first demonstrated. Their applications in proton exchange membrane eletrolyzer cells have been explored in-situ in a cell and characterized ex-situ with SEM and XRD. Compared with the conventional woven liquid/gas diffusion layers (LGDLs), much better performance with EBM fabricated LGDLs is obtained due to their significant reduction of ohmic loss. The EBM technology components exhibited several distinguished advantages in fabricating gas diffusion layer: well-controllable pore morphology and structure, rapid prototyping, fast manufacturing, highly customizing and economic. In addition, by taking advantage of additive manufacturing, it possible to fabricate complicated three-dimensional designs of virtually any shape from a digital model into one single solid object faster, cheaper and easier, especially for titanium. More importantly, this development will provide LGDLs with control of pore size, pore shape, pore distribution, and therefore porosity and permeability, which will be very valuable to develop modeling and to validate simulations of electrolyzers with optimal and repeatable performance. Further, it will lead to a manufacturing solution to greatly simplify the PEMEC/fuel cell components and tomore » couple the LGDLs with other parts, since they can be easily integrated together with this advanced manufacturing process« less
 [1] ;  [1] ;  [2] ;  [2] ;  [2] ;  [2]
  1. Univ. of Tennessee, Knoxville, Tullahoma, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Grant/Contract Number:
AC05-00OR22725; FE0011585
Accepted Manuscript
Journal Name:
International Journal of Hydrogen Energy
Additional Journal Information:
Journal Volume: 41; Journal Issue: 4; Journal ID: ISSN 0360-3199
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A); USDOE National Energy Technology Lab. (United States)
Country of Publication:
United States
43 PARTICLE ACCELERATORS; 3D printing; electron beam melting additive manufacturing; proton exchange membrane electrolyzer cell; liquid/gas diffusion layers; multifunctional materials; 36 MATERIALS SCIENCE
OSTI Identifier:
Alternate Identifier(s):
OSTI ID: 1261266; OSTI ID: 1352948