Review on Proton Exchange Membrane Fuel Cell's Metallic Bipolar Plate Fabrication Challenges

Background: Proton exchange membrane fuel cells (PEMFCs) are promising clean energy converting device that has recently attracted the attention of many electricity -consuming industries. The substitution of graphite bipolar plates (BPs) with metallic BPs broadens PEMFC applications to vibration -dominated areas. Traditional BPs contribute approximately 30-50% to cost, 60-85% to weight, and 60-90% to the cell overall volume. Methods: In this study, the forming methods and critical failure characteristics of metal BPs are investigated. Stamping and pressing are common and inexpensive methods adopted in metallic BP forming. From the recorded literature, this study presents a novel hybrid forming process that is effective in mitigating thinning and dents, which are critical failure parameters. Significant findings: Thinning, dents, and rupture are critical failure parameters in metallic BPs. Failure is more common in bends. This state-of-the-art technique constitutes lubricated roller-fashioned dice. It is effective in both straight channels and lattice patterns. This novel technique is estimated to have a 100% feel -up ratio and 80% thinning reduction.