AEM's hero? The impact of nickel felt PTLs

Nickel is no stranger to electrochemical applications. In the world of hydrogen production, nickel has proven to be an efficient, durable component material. This is particularly true in terms of Anion Exchange Membrane (AEM) electrolyzers.Nickel felt, with its inherent characteristics of conductivity, corrosion resistance, and structural flexibility, serves as a strong option for Porous Transport Layers (PTLs) in corrosive environments. But how does this material fit within the evolving landscape of AEM, and what role will it play in hybrid electrolyzer designs of the future?

AEM electrolyzers bridge the gap between PEM (Porous Exchange Membrane) efficiency and alkaline affordability. Their ability to run on lower-cost materials — including nickel — opens a path to more scalable, economically viable green hydrogen production. As developers aim to cut system costs without compromising performance, AEM has become a key technology to watch.

Nestled between the catalyst layer and the flow field, the PTL enables the transport of electrons while facilitating the distribution and removal of gases. It’s here where nickel excels. Its high electrical conductivity minimizes resistance, while its 3D fibrous structure offers a large contact area that reduces energy losses. That same porous, flexible network also provides the mechanical support necessary to maintain compression and constant contact between components, while the strong corrosion resistance under alkaline media ensures its durability. With efficient water access, rapid gas evacuation, and enhanced electrochemically active sites, nickel felt:

Improves hydrogen production rates

Prevents performance-limiting blockages

Boost overall stack reliability

But its overall durability in harsh environments is where the power of nickel truly lies. This characteristic is critical for the long-term stability of AEM electrolyzers. Unlike other metals prone to corrosion, nickel withstands oxidative degradation and maintains mechanical integrity under the stresses of continuous electrolysis operations. In fact, recent research shows that nickel-based PTLs not only conduct electrons effectively but also contribute catalytically to the oxygen evolution reaction (OER) at the anode in supporting electrolyte. This is accomplished by forming active nickel oxyhydroxide surface species. This dual role further boosts reaction kinetics, allowing AEM systems with nickel PTLs to operate at high current densities with lower overpotentials.

As interest in hybrid electrolyzers continues to grow, nickel PTLs have gained traction in AEM electrolyzers due to their balance of cost, durability, and performance. They not only represent a cost competitive option, but also achieve competitive electrochemical efficiency. Companies and researchers focus on optimizing nickel PTL morphology. Pore size, thickness, and surface properties all play a role in pushing the boundaries of hydrogen generation efficiency. The continued adoption of nickel felt PTLs marks a significant step forward in terms of scalability and economic feasibility of hydrogen production.

Nickel’s unique combination of chemical stability, excellent conductivity, and mechanical robustness make it an indispensable material for PTLs in AEM electrolyzers. By enhancing electron transport, facilitating effective gas and water management, and contributing to catalytic activity, nickel felt PTLs address critical pain points in hydrogen generation. As the hydrogen market evolves, nickel-based PTLs will continue to be a cornerstone technology driving the next generation of efficient, durable, and affordable AEM electrolyzers.

Interested in learning more? Check out what we're up to at our Hydrogen Innovation Hub.