Multiphase flow dynamics in metal foam proton exchange membrane fuel cell

Porous metal foam holds substantial promise as a material for bipolar plates in high-performance proton exchange membrane fuel cells (PEMFC) due to its exceptional properties in reactant redistribution. However, the intricate structure of metal foam flow field (MFF) presents challenges for mass transfer and water management. In this study, a three-dimensional two-phase flow model for metal foam is developed to analyze and capture flow patterns. MFFs are reconstructed based on detailed structural analysis and various pore sizes are discussed. Employing the Volume of Fluid (VOF) method, we delve into multiphase flow dynamics, specifically focusing on the removal of liquid droplets within the MFF. It reveals the MFF with moderate pore sizes exhibit a trade-off performance, striking a balance between optimal mass transfer and minimal parasitic loss. The porous structure's pivotal role is highlighted, contributing significantly to both through-plane and in-plane mass transfer and convection. Furthermore, we classify three flow patterns of liquid droplet, with the “split-up” pattern emerging as the most effective for water management and mass transfer. This study illuminates water behavior in porous metal foam bipolar plates, introduces a systematic methodology for assessing mass transfer and water management capabilities in MFFs for PEMFC.