METAL FOAM GAS DIFFUSION LAYERS AND POLYMER-ELECTROLYTE-MEMBRANE FUEL CELLS WITH METAL FOAM GAS DIFFUSION LAYERS

A bipolar plate-gas diffusion layer (GDL) assembly for a polymer-electrolyte-membrane fuel cell includes a flat metallic bipolar plate and a porous metal GDL adjacent to and in direct contact with the flat metallic bipolar plate. The porous metal GDL includes flow channels defined by flow channels walls with flow channel surfaces. The flow channel walls and flow channel surfaces have an average porosity generally equal to an average porosity of an interior of the porous metal GDL.