Feasibility investigations on a novel micro-manufacturing process for fabrication of fuel cell bipolar plates: Internal pressure-assisted embossing of micro-channels with in-die mechanical bonding

被引:100
作者
Koc, Mummer [1 ]
Mahabunphachai, Sasawat
机构
[1] Virginia Commonwealth Univ, Dept Mech Engn, NSF I UCR Ctr Precis Forming CPF, Richmond, VA 23284 USA
[2] Univ Michigan, Dept Mech Engn, Ann Arbor, MI 48109 USA
基金
美国国家科学基金会;
关键词
fuel cell; micro-manufacturing; micro-channel; hydroforming; mechanical bonding;
D O I
10.1016/j.jpowsour.2007.05.089
中图分类号
O64 [物理化学(理论化学)、化学物理学];
学科分类号
070304 ; 081704 ;
摘要
In this paper, we present the results of our studies on conceptual design and feasibility experiments towards development of a novel hybrid manufacturing process to fabricate fuel cell bipolar plates that consists of multi-array micro-channels on a large surface area. The premises of this hybrid micro-manufacturing process stem from the use of an internal pressure-assisted embossing process (cold or warm) combined with mechanical bonding of double bipolar plates in a single-die and single-step operation. Such combined use of hydraulic and mechanical forming forces and in-process bonding will (a) enable integrated forming of micro-channels on both surfaces (as anode and cathode flow fields) and at the middle (as cooling channels), (b) reduce the process steps, (c) reduce variation in dimensional tolerances and surface finish, (d) increase the product quality, (e) increase the performance of fuel cell by optimizing flow-field designs and ensuring consistent contact resistance, and (f) reduce the overall stack cost. This paper explains two experimental investigations that were performed to characterize and evaluate the feasibility of the conceptualized manufacturing process. The first investigation involved hydroforming of micro-channels using thin sheet metals of SS304 with a thickness of 51 mu m. The width of the channels ranged from 0.46 to 1.33 mm and the height range was between 0.15 and 0.98 mm. Our feasibility experiments resulted in that different aspect ratios of micro-channels could be fabricated using internal pressure in a controllable manner although there is a limit to very sharp channel shapes (i.e., high aspect ratios with narrow channels). The second investigation was on the feasibility of mechanical bonding of thin sheet metal blanks. The effects of different process and material variables on the bond quality were studied. Successful bonding of various metal blanks (Ni201, A13003, and SS304) was obtained. The experimental results from both investigations demonstrated the feasibility of the proposed manufacturing technique for making of the fuel cell bipolar plates. (c) 2007 Elsevier B.V. All rights reserved.
引用
收藏
页码:725 / 733
页数:9
相关论文
共 29 条
  • [21] Fuel cell system economics: comparing the costs of generating power with stationary and motor vehicle PEM fuel cell systems
    Lipman, TE
    Edwards, JL
    Kammen, DM
    [J]. ENERGY POLICY, 2004, 32 (01) : 101 - 125
  • [22] Interface surface behaviour in the upsetting of sandwich metal sheets
    Lukaschkin, ND
    Borissow, AP
    [J]. JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 1996, 61 (03) : 292 - 297
  • [23] Review and analysis of PEM fuel cell design and manufacturing
    Mehta, V
    Cooper, JS
    [J]. JOURNAL OF POWER SOURCES, 2003, 114 (01) : 32 - 53
  • [24] Bipolar plates for PEM fuel cells
    Middelman, E
    Kout, W
    Vogelaar, B
    Lenssen, J
    de Waal, E
    [J]. JOURNAL OF POWER SOURCES, 2003, 118 (1-2) : 44 - 46
  • [25] The electrical and physical properties of alternative material bipolar plate for PEM fuel cell system
    Oh, MH
    Yoon, YS
    Park, SG
    [J]. ELECTROCHIMICA ACTA, 2004, 50 (2-3) : 777 - 780
  • [26] Investigations on novel low-cost graphite composite bipolar plates
    Scholta, J
    Rohland, B
    Trapp, V
    Focken, U
    [J]. JOURNAL OF POWER SOURCES, 1999, 84 (02) : 231 - 234
  • [27] Stainless steel as bipolar plate material for polymer electrolyte membrane fuel cells
    Wang, HL
    Sweikart, MA
    Turner, JA
    [J]. JOURNAL OF POWER SOURCES, 2003, 115 (02) : 243 - 251
  • [28] Metallic bipolar plates for PEM fuel cells
    Wind, J
    Späh, R
    Kaiser, W
    Böhm, G
    [J]. JOURNAL OF POWER SOURCES, 2002, 105 (02) : 256 - 260
  • [29] Zhang W., 1996, CIRP ANN-MANUF TECHN, V45, P215, DOI DOI 10.1016/S0007-8506(07)63050-9