Additive manufacturing of titanium porous transport layers for enhanced performance in proton exchange membrane water electrolysis

Mechanical and Mechatronic Engineering Department, Faculty of Engineering, Stellenbosch University, Stellenbosch, South Africa

^* Corresponding author: gterhaar@sun.ac.za

Abstract

This study investigates the feasibility of using Laser Powder Bed Fusion (L-PBF) additive manufacturing (AM) to fabricate porous titanium Porous Transport Layers (PTLs) for Proton Exchange Membrane Water Electrolysis (PEMWE) systems. We explore L-PBF as a potential solution to overcome limitations of traditional PTL manufacturing methods, such as limited control over structural morphology and inefficient material use. Using spheroidized titanium powder, we produced 1 mm thick plates with varying porosities by manipulating laser process parameters. The internal structure and surface morphology of AM-produced PTLs were characterized and compared to conventional press-sintered PTLs. L-PBF successfully produced PTLs with porosities in the recommended 30-50% range, featuring spherical particles and a textured pore structure. In-situ testing in a lab-scale PEMWE revealed that AM-produced PTLs exhibited improved performance compared to commercial press-sintered PTLs. This enhancement is attributed to the finer surface structure and favourable gas liquid transport properties of the AM-produced PTLs. These preliminary findings suggest that L-PBF is a promising method for manufacturing PTLs, offering potential advantages in design flexibility, material efficiency, and PEMWE performance. Further research is needed to fully optimize the AM process and comprehensively evaluate long-term PTL performance.