| Summary: | The optimization of reactant and product mass transfer within fuel cells stands as a critical determinant for achieving optimal fuel-cell performance. With a specific focus on stationary applications, this study delves into the comprehensive examination of fuel-cell mass transfer properties, employing a sophisticated blend of computational fluid dynamics (CFD) and the innovative design of a double-layered wire mesh (DLWM) as a flow field and gas diffusion layer. The investigation notably contrasts a meticulously developed 3D fine mesh flow field with a numerical model of the integrated DLWM implemented on the cathode end of a proton exchange membrane fuel cell (PEMFC). Evaluations reveal that the 3D fine mesh experiences a notable threefold increase in pressure drop compared to the DLWM flow field, indicative of the enhanced efficiency achieved by the DLWM configuration. Oxygen distribution analyses further underscore the promising performance of both the 3D fine mesh and the proposed DLWM, with the DLWM showcasing additional improvements in water removal capabilities within the cell. Impressively, the DLWM attains a remarkable maximum current density of 2137.17 mA/cm<sup>2</sup> at 0.55 V, indicative of its superior performance over the 3D fine mesh, while also demonstrating the potential for cost-effectiveness and scalability in mass production.
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