Understanding the impact of the gas diffusion layer structure on catalyst utilization in the PEM water electrolyzer

A multiphysics half-cell model of a polymer electrolyte membrane water electrolyzer (PEMWE) was developed to probe impacts of the detailed 3-dimensional pore structure of the gas diffusion layer (GDL) on performance characteristics. We show that pores in the titanium GDL mesh led to significant underutilization of the catalyst layer (CL), with only 45% of the catalyst effectively utilized. This contradicts the assumption of uniform electron flow across the CL, as shown in graphical abstract (a), as near-zero current was observed near GDL pore regions and the current distribution in CL was influenced by GDL structure, as shown in graphical abstract (b). Instead, oxygen generation was primarily concentrated under the solid titanium regions, diffusing out around the pore walls. High current density peaks were also noted at the GDL-catalyst contact, correlating with degradation hotspots that were directly observed in companion experiments, as shown in graphical abstract (c). Collectively, these findings point to the critical importance of the heterogeneous GDL porous architecture not only for PEMWE efficiency but also for uneven degradation of the CL. • Revealed the impacts of the GDL pore structure on PEMWE performance in a model. • Pores in GDL led to uneven current distribution and oxygen generation rate in CL. • Pores in the GDL led to significant underutilization of the CL (45% of CL). • Impact of CL electrical conductivity on CL utilization was limited. • A non-uniform CL was examined to improve the catalyst utilization on the anode.