| Summary: | Proton exchange membrane fuel cell (PEM-FC) aggregation pressure causes extensive strains in cell segments. The compression of each segment takes place through the cell modeling method. In addition, a very heterogeneous compressive load is produced because of the recurrent channel rib design of the dipole plates, so that while high strains are provided below the rib, the domain continues in its initial uncompressed case under the ducts approximate to it. This leads to significant spatial variations in thermal and electrical connections and contact resistances (both in rib–GDL and membrane–GDL interfaces). Variations in heat, charge, and mass transfer rates within the GDL can affect the performance of the fuel cell (FC) and its lifetime. In this paper, two scenarios are considered to verify the performance and lifetime of the PEM-FC using different innovative channel geometries. The first scenario is conducted by adopting a constant channel height (H = 1 mm) for all the differently shaped channels studied. In contrast, the second scenario is conducted by taking a constant channel cross-sectional area (A = 1 mm<sup>2</sup>) for all the studied channels. Therefore, a computational fluid dynamics model (CFD) for a PEM fuel cell is formed through the assembly of FC to simulate the pressure variations inside it. The simulation results showed that a triangular cross-section channel provided the uniformity of the pressure distribution, with lower deformations and lower mechanical stresses. The analysis helped gain insights into the physical mechanisms that lead to the FC’s durability and identify important parameters under different conditions. The model shows that it can assume the intracellular pressure configuration toward durability and appearance containing limited experimental data. The results also proved that the better cell voltage occurs in the case of the rectangular channel cross-section, and therefore, higher power from the FC, although its durability is much lower compared to the durability of the triangular channel. The results also showed that the rectangular channel cross-section gave higher cell voltages, and therefore, higher power (0.63 W) from the fuel cell, although its durability is much lower compared to the durability of the triangular channel. Therefore, the triangular channel gives better performance compared to other innovative channels.
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