Effect of manufacturing processes on contact resistance characteristics of metallic bipolar plates in PEM fuel cells

Contact resistance characteristics of coated metallic bipolar plates for PEM fuel cells – investigations on the effect of manufacturing

“…Stamping and hydroforming are noted to be the most suitable approaches for mass production of BPPs as discussed in previous publications available in the literature [51e61]. In a previous study by authors, the effect of these two manufacturing methods on ICR of uncoated metallic BPPs was investigated [62]. It was concluded that manufacturing process, process conditions and die geometry affect the ICR to different extents.…”

“…To begin with, 51 mm thick SS316L sheets in annealed condition were shaped into micro-channeled surfaces (BPP) using stamping and hydroforming processes as explained in detail in a previous publication by authors [62]. Formed plates, then, were outsourced for PVD coating (Tanury Industries Co., Lincoln, RI).…”

“…In forming of bipolar plates using hydroforming and stamping processes, pre-determined process parameters from previous studies were 40 MPa hydroforming pressure with 1 MPa/s rate in hydroforming, and 200 kN stamping force with 1 mm/s punch speed [51,62]. Necessary sheet sizes for forming process were 70 Â 70 mm in stamping and 150 Â 150 mm in hydroforming while formed (micro-channeled) areas were limited to 40 Â 40 mm in both processes.…”

“…1. Detailed description of the forming processes benefited can be found elsewhere in literature [62,63].…”

Fabrication of Aluminum Bipolar Plates by Semi‐solid Forging Process and Performance Test of TiN Coated Aluminum Bipolar Plates

“…Research on manufacturing processes to fabricate metallic bipolar plates has mainly been twofold: some methods use solid materials with stamping [8,9], hydroforming [8], rubber pad forming [10,11], and machining [12,13], while other methods use liquid materials with vacuum die casting [14,15]. Stamping, rubber pad forming, and hydroforming are appropriate for mass production, and have forming limitations in terms of spring-back and flatness after forming.…”