Cold start simulation study at the key material level of fuel cell

Cold start simulation analysis is widely recognized in the industry as an efficient approach for rapidly developing cold start strategies and improving start-up performance. Currently, one-dimensional models are commonly employed to quickly investigate the thermo-hydraulic behavior of fuel cells under various start-up strategies, while three-dimensional models offer more intuitive insights into internal mass transport and phase change phenomena. However, the influence of key material properties on cold start performance remains insufficiently explored and warrants further investigation. Accordingly, this study develops a one-dimensional multiphase model to investigate how key material parameters affect fuel cell cold start performance. Results show that optimizing parameters such as the thickness and contact angle of the catalyst layer, gas diffusion layer thickness, and membrane thickness can significantly reduce ice formation and improve cold start success. Specifically, thicker gas diffusion layers enhance moisture management, while an 8-μm catalyst layer balances ice accommodation and voltage output. Higher contact angles lower freezing points, and increased membrane thickness delays freezing and boosts internal heat. These optimizations notably improve cold start performance at − 10 °C and − 15 °C.