Koorata, P.K.2026-02-042022Journal of the Electrochemical Society, 2022, 169, 10, pp. -134651https://doi.org/10.1149/1945-7111/ac9a7dhttps://idr.nitk.ac.in/handle/123456789/22370The deformation mechanics of a typical gas diffusion layer using experimental and advanced modelling technique is reported. The experimental cyclic response is observed similar to pseudo-elastic materials with highly nonlinear loading/unloading. The cyclic compressive mechanical response of gas diffusion layer (GDL) is modelled to be the outcome of cumulative changes in deformation kinematics of matrix and fiber fractions. The individual mechanisms necessitating the energy dissipation, residual strain, and stress softening during cyclic mechanical response are related to nonlinear hyperelastic matrix with the damage function and inelastic activation function at the interface of constituents. The model predicts highly nonlinear elastic loading, residual strain, hysteresis, and damage quotient associated with stress softening as a function of several cycles. The significant takeaway from this study is in terms of quantifying strength, inelastic nature of individual constituents. The proposed model is simulated for low-level altering stresses of up to twenty cycles. The results show the build-up of residual strains and hysteresis as a function of fuel cell clamping pressure. © 2022 The Electrochemical Society (“ECS”). Published on behalf of ECS by IOP Publishing Limited.DeformationDiffusion in gasesEnergy dissipationHysteresisMechanismsStrainStress analysisStructural designAdvanced modeling techniquesCyclic responseDeformation mechanicsExperimental modellingFuel cells gasGas diffusion layersMechanical responsePseudo-elastic materialsResidual strainsStress softeningFuel cells