Reactive impinging flow (RIF) is a novel quality-control method for defect detection (i.e., reduction in Pt catalyst loading) in gas-diffusion electrodes (GDEs) on weblines. The technique uses infrared thermography to detect temperature of a nonflammable ( <
4% H 2 ) reactive mixture of H 2 /O 2 in N 2 impinging and reacting on a Pt catalytic surface. In this paper, different GDE size defects (with catalyst-loading reductions of 25, 50, and 100%) are detected at various webline speeds (3.048 and 9.144 m min -1 ) and gas flowrates (32.5 or 50 standard L min -1 ). Furthermore, a model is developed and validated for the technique, and it is subsequently used to optimize operating conditions and explore the applicability of the technique to a range of defects. The model suggests that increased detection can be achieved by recting more of the impinging H 2 , which can be accomplished by placing blocking substrates on the top, bottom, or both of the GDE
placing a substrate on both results in a factor of four increase in the temperature differential, which is needed for smaller defect detection. Overall, the RIF technique is shown to be a promising route for in-line, high-speed, large-area detection of GDE defects on moving weblines.