Gas Diffusion Layers in Fuel Cells and Electrolysers: A Novel Semi-Empirical Model to Predict Electrical Conductivity of Sintered Metal Fibres

This paper introduces novel empirical as well as modified models to predict the electrical conductivity of sintered metal fibres and closed-cell foams. These models provide a significant improvement over the existing models and reduce the maximum relative error from as high as just over 30% down to about 10%. Also, it is shown that these models provide a noticeable improvement for closed-cell metal foams. However, the estimation of electrical conductivity of open-cell metal foams was improved marginally over previous models. Sintered porous metals are widely used in electrochemical devices such as water electrolysers, unitised regenerative fuel cells (URFCs) as gas diffusion layers (GDLs), and batteries. Having a more accurate prediction of electrical conductivity based on variation by porosity helps in better modelling of such devices and hence achieving improved designs. The models presented in this paper are fitted to the experimental results in order to highlight the difference between the conductivity of sintered metal fibres and metal foams. It is shown that the critical porosity (maximum achievable porosity) can play an important role in sintered metal fibres to predict the electrical conductivity whereas its effect is not significant in open-cell metal foams. Based on the models, the electrical conductivity reaches zero value at 95% porosity rather than 100% for sintered metal fibres.