Session: 15-01-01: ASME International Undergraduate Research and Design Exposition

Paper Number: 142399

142399 - Development of a Superhydrophobic Ceramic Coating for Application in Proton Exchange Membrane Fuel Cells 

The research presented here gives greater understanding of, and advancements in, the use of ceramic superhydrophobic coatings for proton exchange membrane fuel cell (PEMFC) bipolar plates. PEMFC operating temperature is ~90 ^oC, and as a result, liquid water is formed at the cathode bipolar plate as hydrogen and oxygen are combined. This introduces multiphase flow, and the associated challenges with multiphase flow, such as water droplets clogging the exhaust channels. These difficulties with mass transport negatively impact the overall efficiency of the cell. It is desirable to remedy this issue in order to improve PEMFC performance and motivate their usage as green energy conversion devices. One strategy to alleviate this problem is by raising the operational temperature of the cell to over 100 ^oC, ensuring water is exhausted as a vapor, but this introduces issues with the membrane drying during operation, causing other significant performance losses. The alternative option is to facilitate the removal of water from the cathode. This can be done passively and actively. Acoustic pressure waves can be used to dislodge well-adhered water slugs in active control strategies, while the use of hydrophobic and hydrophilic coatings on the channels allows for passive control of the transport of the water droplets. A hydrophobic ceramic coating is explored in this work to aid in water removal while also providing corrosion protection, a useful benefit given the elevated temperature, reducing environment, and high humidity the metallic bipolar plates are exposed to during operation. Much research has been dedicated to the use of ceramic coatings in many industries where hydrophobicity is valuable, and much research has looked at using ceramic coatings as corrosion protection in PEMFCs, but less work has been done looking at hydrophobic ceramic coating usage in PEMFCs. The goal of this project is to create a ceramic superhydrophobic coating to decrease the clogging of the exhaust channels. A variety of ceramic coatings consisting of alumina, yttria-stabilized zirconia, and silica were applied to an anodized aluminum plate using aerosol spray deposition. Some of these base powders were also modified using aerosol assisted self-assembly to coat the ceramic particles in hydrophobic groups. This film was then characterized using scanning electron microscopy, optical microscopy, and 3D scanning to obtain microscale and mesoscale structure. Contact angle measurements were then obtained using a Ráme-hart goniometer to measure the degree of hydrophobicity. Initial results have shown aerosol spray deposition is a facile method for depositing ceramic coatings on materials with complex geometries, and allows for tailoring of the properties of the base material. The information gathered as part of this study will inform future application of the films and deposition process developed here in PEMFCs, as well as other high-interest areas, such as anti-icing coatings for heat exchangers and aircraft.

 

 

 

Presenting Author: Gabriel Sayre western new england university

Presenting Author Biography: I am a Junior Mechanical Engineering Student set to graduate in May 2025. I worked with Professor, Alexander Hartwell and co-authors this past fall and spring semesters 2023-2024, on the Superhydrophobic ceramic coatings for fuel cells.

Authors:

Gabriel Sayre western new england university
Jason Chartier western new england university
Trevor Relyea western new england
Sebastian Manning western new england university
Alexander Hartwell western new england university