Accelerating the PEM fuel cell development cycle by predicting large-format stack performance and durability from subscale membrane electrode assembly testing

Eligibility: UK/International (including EU) graduates with the required entry requirements

Duration: Full-time – between three and three and a half years fixed term

Application deadline: 25 Aug 2026

Interview date: Will be confirmed to shortlisted candidates

Start date: January 2027

For further details contact: Associate Professor Sumit Roy

Introduction

Proton exchange membrane fuel cells (PEMFCs) are central to hydrogen-electric transport, stationary power and emerging heavy-duty applications, but development remains constrained by the cost, duration and limited availability of representative performance and durability testing. Industrial practice already uses subscale single-cell testing to screen MEAs and components before scale-up; however, test results can be strongly hardware-dependent, with mass transport in the gas diffusion layer, microporous layer and catalyst layer influenced by the cell hardware and operating environment. Harmonised single-cell test protocols have therefore been developed to compare MEA performance and durability under automotive-relevant operating conditions.

The scientific basis for translating subscale performance and durability data to large-format cells remains incomplete. Published work on PEMFC scale-up reports contradictory outcomes, with some studies showing reduced performance on scale-up and others showing improved performance when water management is adequate. Large-format performance is influenced by reactant distribution, pressure drop, compression, thermal gradients, flow-field architecture and water management, all of which can obscure intrinsic electrode behaviour.

This project will exploit Coventry University’s PEMFC test capability at 12 cm², 45 cm² and 250 cm² to establish when subscale tests can reliably predict large-format PEMFC performance and durability, and when scale-dependent effects invalidate such predictions. The project is directly relevant to industrial PEMFC developers, who must often commit costly and sequential test-stand capacity to full-format cells or short stacks before understanding whether candidate MEAs, GDLs or electrode architectures justify scale-up.

The project is offered as a Coventry University–Stellenbosch University cotutelle PhD, providing an outstanding international training and development environment. The student will be based primarily within Coventry University’s hydrogen research group, working with supervisors experienced in PEMFC diagnostics, electrochemical engineering, MEA materials, modelling and industrial fuel cell development. In Year 2, the student will undertake a 3 month research stay at Stellenbosch University to evaluate the reproducibility of the scale-transfer methodology across laboratories.

Project details

This PhD aims to address challenges associated with fuel cell scale-up by developing and validating a scale-transfer methodology for PEMFC performance and durability. The project will use Coventry University’s established PEMFC test capability at 12 cm², 45 cm² and 250 cm² to determine when subscale tests can predict large-format operation, and when scale-dependent effects such as reactant distribution, pressure drop, compression, thermal gradients, flow-field architecture and water management invalidate direct comparison. The work will provide practical guidance for PEMFC developers on how much confidence can be placed in subscale screening data, where correction factors are needed, and when full-format or stack-level validation remains essential.

The student will undertake a structured programme of experimental and modelling work. Initial activity will include a literature review of PEMFC active-area scaling, MEA screening practice, harmonised single-cell protocols, flow-field effects, water management, degradation mechanisms and reduced-order modelling. Nominally equivalent MEAs will then be fabricated or sourced for testing across the three cell formats.

Experimental diagnostics will include polarisation curves, high-frequency resistance, electrochemical impedance spectroscopy, oxygen/air diagnostics, limiting-current measurements and selected pressure, humidity and stoichiometry sensitivity tests. These methods will be used to separate kinetic, ohmic and mass-transport contributions and identify which electrochemical descriptors remain transferable across active area and hardware scale. Targeted durability and accelerated stress testing will then be used to compare voltage decay, electrochemical surface area loss, resistance changes and mass-transport degradation across scales.

A key outcome will be a reduced-order or physics-informed model linking subscale diagnostics to 250 cm² performance and, where available, stack-relevant behaviour. Candidate approaches may include empirical regression, dimensionless descriptors, equivalent-circuit parameterisation and relationships informed by geometry, operating conditions and flow-field characteristics. The model will be validated against withheld large-format data, cross-site testing and available stack-build or stack-test data.

By improving the reliability of subscale screening, this project will help reduce the cost, risk and time required to develop next-generation PEMFC components and stacks. The research is directly relevant to companies developing fuel cells for transport, aviation, marine, stationary power and other hydrogen applications, and will position the student for future careers in electrochemical engineering, hydrogen technology, industrial R&D, modelling or academic research.

Funding

Tuition fees and bursary.

Benefits

The successful candidate will receive comprehensive research training including technical, personal and professional skills. All researchers at Coventry University (from PhD to Professor) are part of the Doctoral and Researcher College, which provides support with high-quality training and career development activities.

Entry requirements

A minimum of a 2:1 first degree in a relevant discipline/subject area with a minimum 60% mark in the project element or equivalent with a minimum 60% overall module average.

PLUS

A master's degree in a relevant subject area.The master's must have been attained with minimum overall marks at merit level (60%)*. In addition, the dissertation or equivalent element in the master's must also have been attained with a minimum mark of merit level (60%).
The potential to engage in innovative research and to complete the PhD within 3.5 years.
A minimum of English language proficiency (IELTS academic overall minimum score of 7.0 with a minimum of 6.5 in each component).

Additional requirements

This studentship would suit a motivated candidate with a background in chemical engineering, mechanical engineering, materials science, electrochemistry, energy systems or a closely related discipline. Experience with fuel cells, electrochemical testing, data analysis, modelling or experimental engineering would be advantageous, but training will be provided. The successful candidate will develop advanced skills in PEMFC testing, diagnostics, durability assessment, data-driven and physics-informed modelling, international research collaboration and communication with academic and industrial stakeholders.

Essential skills and knowledge

A first-class or upper second-class honours degree (or equivalent) in Chemical Engineering, Mechanical Engineering, Materials Science, Electrochemistry, Energy Systems, or a closely related discipline.
An interest in fuel cell technology and electrochemical energy conversion, particularly PEMFC performance and durability.
Strong analytical and critical thinking skills, with the ability to synthesise complex experimental data and develop well-reasoned technical conclusions.
An understanding of experimental methods and a willingness to apply these to real-world engineering problems.
Excellent written and verbal communication skills, with the ability to present complex technical ideas clearly to both technical and non-technical audiences.
The ability to work independently while contributing effectively within a multidisciplinary research environment.
Strong organisational skills and the ability to manage a long-term research project.

Desirable knowledge and experience

Familiarity with fuel cells, electrolysers or other electrochemical energy devices.
Knowledge of electrochemical diagnostic techniques such as polarisation curves and electrochemical impedance spectroscopy.
Experience with experimental rig design, test-stand operation or laboratory-based electrochemical testing.
Experience with data analysis, modelling or reduced-order/physics-informed modelling approaches.
Familiarity with membrane electrode assembly (MEA) fabrication or characterisation.
Understanding of durability and degradation mechanisms in electrochemical devices.
Experience using programming or modelling tools such as MATLAB or Python.
Awareness of industrial fuel cell development processes and scale-up challenges.

How to apply

To find out more about the project, please contact Associate Professor Sumit Roy.

All applications require full supporting documentation, a covering letter, plus a 2000-word supporting statement showing how the applicant’s expertise and interests are relevant to the project.

Apply to Coventry University