Mechanical characterization and durability of sintered porous transport layers for polymer electrolyte membrane electrolysis

Differential pressure electrolysis offers the potential for more efficient hydrogen compression. Due to the differential pressures acting within the electrolytic cell, the porous transport layer (PTL) is subjected to high stress. For safety reasons, the PTL's mechanical stability must be ensured. However, the requirements for high porosity and low thickness stand in contrast to that for mechanical stability. Porous transport layers for polymer electrolyte membrane (PEM) electrolysis are typically prepared by means of the thermal sintering of titanium powder. Thus far, the factors that influence the mechanical strength of the sintered bodies and how all requirements can be simultaneously fulfilled have not been investigated. Here, the static and dynamic mechanical properties of thin sintered titanium sheets are investigated ex-situ via tensile tests and periodic loading in a test cell, respectively. In order for a sintered PTL with a thickness of 500 μm and porosities above 25% to be able to withstand 50 bar differential pressure in the cell, the maximum flow field width should be limited to 3 mm. Thus, a method was developed to test the suitability of PTL materials for use in electrolysis for various differential pressures and flow field widths.