Effect of graphite addition into mill scale waste as a potential bipolar plates material of proton exchange membrane fuel cells

Bipolar plates (BPP) is a vital component of proton exchange membrane fuel cells (PEMFC), which supplies fuel and oxidant to reactive sites, remove reaction products, collects produced current and provide mechanical support for the cells in the stack. This work concerns the utilization of mill scale, a by-product of iron and steel formed during the hot rolling of steel, as a potential material for use as BPP in PEMFC. On the other hand, mill scale is considered a very rich in iron source having characteristic required such as for current collector in BPP and would significantly contribute to lower the overall cost of PEMFC based fuel cell systems. In this study, the iron reach source of mill scale powder, after sieving of 150 mesh, was mechanically alloyed with the carbon source containing 5, 10, and 15 wt.% graphite using a shaker mill for 3 h. The mixed powders were then pressed at 300 MPa and sintered at 900 degrees C for 1 h under inert gas atmosphere. The structural changes of powder particles during mechanical alloying and after sintering were studied by X-ray diffractometry, optical microscopy, scanning electron microscopy, and microhardness measurement. The details of the presence of iron, carbon, and iron carbide (Fe-C) as the products of reactions as well as sufficient mechanical strength of the sintered materials were presented in this report.