Sensitivity analysis and performance optimization of PEM fuel cells coupling vibration and compression

Proton exchange membrane fuel cells (PEMFCs) encounter significant challenges in predicting performance under complex mechanical loads in vehicles and ships. Existing models focus on isolated factors like vibration or assembly pressure, failing to accurately capture the dynamic responses under the coupled conditions. To address this limitation, this study develops a coupled multi-physics model integrating dynamic vibration and static compression stress. Orthogonal experimental design method is applied to quantify the effects of vibration frequency, amplitude, and assembly pressure, as well as their interaction weights. The coupling impact of vibration-compression on membrane electrode assembly deformation and mass transfer processes are elucidated. The results reveal 0.7 MPa as the optimal assembly pressure, balancing electro-thermal conduction and mass transfer resistance. Vibration intensifies uneven reactant gas distribution, altering current density and diminishing cell performance and stability. The assembly pressure contributes 90% to performance, with vibration at 10%. To mitigate degradation, the vibration amplitude should remain below 0.8 mm/s, avoiding the sensitive frequency range of 4–10 Hz. This coupled model and optimization insights offer valuable guidance for PEMFCs stack design, vibration mitigation, and durability improvement in demanding environments.