Effect of gas diffusion layer surface property on platinum nanowire array electrode performance in proton exchange membrane fuel cells

3D-ordered catalyst electrodes have been recognized as one effective strategy to reach high current density operation for proton exchange membrane fuel cell (PEMFC) applications. Gas diffusion electrodes (GDEs) with platinum nanowire arrays in-situ grown on gas diffusion layer (GDL) surface is an important contribution in this area, but the performance is highly dependent on the GDL surface properties. In this study, the GDLs available in the market are systematically investigated, with a focus on the influence of the GDL surface properties on the in-situ growth of Pt nanowire arrays to fabricate GDEs as cathodes for PEMFCs. The experimental results indicate that mesopores especially micropores play a key role. They enable a hydrophilic surface for the isopropanol pretreated GDL, facilitating the in-situ growth of Pt nanowires to form a uniform array with a large electrochemical surface area (ECSA), finally leading to a high-power density. With Freudenberg H24CX483 carbon paper GDL, the highest power density of 0.9 W cm⁻² is achieved. The understanding achieved here could be further used to develop novel GDLs for fabricating the next generation of electrodes for large current density operations.