Numerical–experimental investigations on the manufacturing of an aluminium bipolar plate for proton exchange membrane fuel cells by warm hydroforming

Palumbo, G.; Piccininni, Antonio

doi:10.1007/s00170-013-5047-1

Cited by 30 publications

(9 citation statements)

References 22 publications

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“…Readers are advised to refer Toros et al 19 for detailed review on warm forming of Al–Mg alloys. Palumbo and Piccininni 20 employed temperature range of 110 °C–220 °C in the warm hydro-forming of AA6061 aluminum alloys. Zhang et al 21 investigated the effects of dynamic forming conditions at elevated temperatures on the FLC using a combination of modified Voce constitutive model with the numerically simulated Marciniak test.…”

Section: Introductionmentioning

confidence: 99%

Elevated temperature forming limit strain diagrams of automotive alloys Al6014-T4 and DP600: A case study

Saxena

Drotleff

Mukhopadhyay

2016

The Journal of Strain Analysis for Engineering Design

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The press formability of the automotive materials such as aluminum alloys, magnesium alloys and steels is influenced by forming temperatures. While adjusting the temperature level of die, punch and binder, the lightweight materials can successfully be formed, especially for complex automotive body parts. The objective of this case study is to determine the forming limit curves of Al6014 and DP600 alloy sheet at elevated temperatures in specific range of 200°C and 250°C suitable for press operation in long-run production cycles. The focus is set on Al6014 and DP600 as these two materials are widely used in automotive panels due to their high strength and lightweight and improved resistance to corrosion. DP600 is sometimes preheated before forming to avoid cracks. Thus, it is essential to study the effect of preheating temperature on the formability. Experiments were conducted at forming temperatures of 200°C and 250°C and at low punch speed. The measurement of train distribution was carried out online using digital image correlation with the optical deformation measurement system GOM Aramis. Both Al6014 and DP600 alloys were found to have good drawability and stretchability. It was found that for Al6014, the forming limit curve level increases with temperature. On the contrary, DP600 showed slight decrease in the level of forming limit curve as temperature was increased. Warm formability for these alloys was further characterized through part depth and percentage thinning measurements.

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Section: Introductionmentioning

confidence: 99%

Elevated temperature forming limit strain diagrams of automotive alloys Al6014-T4 and DP600: A case study

Saxena

Drotleff

Mukhopadhyay

2016

The Journal of Strain Analysis for Engineering Design

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“…The latter researchers studied the effect of various parameters, namely forming speed and die temperature. In addition, Palumbo et al [22] focused on the manufacturing of a bipolar plate from an AA6061 aluminum sheet using a warm hydroforming process. They analyzed both the channel profile and bipolar plate geometry by applying the finite element method (FEM).…”

Section: Introductionmentioning

confidence: 99%

Numerical analyses of Manufacturing of an AA8111 Pin-shaped Bipolar Plate by Hot Metal Gas Forming

2021

IJE

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In this paper, fabrication of a pin-shaped bipolar plate for a proton exchange membrane fuel cell, the deformation behavior of a thin 8111 aluminum alloy sheet by the hot metal gas forming (HMGF) process was investigated. The effect of gas pressure, forming time, pin diameter, pin height, and die fillet radius on the specimen profiles, as well as the thickness distribution were analyzed by finite element method using ABAQUS 6.10 software. In addition, experimental tests were performed to validate numerical outputs. The results indicated that the sheet-thinning rate sharply grew by the gas pressure exceeding 4 MPa. The specimens were cracked following decreasing the die fillet radius to 0.1 mm. Furthermore, the die filling rate was high at the beginning of forming time and then diminished gradually after 1000 s. Moreover, the thickness reduced sharply by augmenting the ratio of pin height to diameter to over 0.4. Finally, perfect specimens were produced in experiments, which verified the feasibility of fabricating a pin-shaped bipolar plate out of a thin AA8111 sheet by the HMGF process.

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“…Metals such as titanium [3], copper [4], aluminum [5], stainless steel [6], carbon steel [7][8][9][10][11][12], and various other alloys [13,14] have been evaluated for PEM fuel cell BPPs. Most of these studies conclude that although the cost of manufacturing is low for metallic bipolar plates, the corrosion resistance is also low and hence are not suitable for BPPs.…”

Section: Introductionmentioning

confidence: 99%

Effect of Cr content on the corrosion resistance of Ni–Cr–P coatings for PEMFC metallic bipolar plates

Chanda

Padhee

Pathak

et al. 2019

Mater Renew Sustain Energy

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In here, we report on the pulse electrodeposition of nickel-chromium-phosphorous (Ni-Cr-P) coatings on AISI 1020 low carbon steel using an aqueous electrolyte consisting of NiCl 2 , CrCl 3 , and NaH 2 PO 2. We evaluated the effectiveness of Ni-Cr-P coatings for polymer electrolyte membrane fuel cell metallic bipolar plates. Coatings deposited at pH 3.0 and room temperature show nearly three orders improvement in corrosion resistance compared to bare AISI 1020. The corrosion current (I corr) of Ni-Cr-P samples coated at 25 °C is 1.16 × 10 −4 A/cm 2 , while that of bare carbon steel is 1.05 × 10 −2 A/cm 2. The improvement in corrosion resistance is due to the increase in Cr content in the Ni-Cr-P coatings. Cr forms a stable oxide barrier layer and inhibits pitting corrosion. The interfacial contact resistance increases with an increase in Cr content and immersion time in the corrosion media. The increase in interfacial contact resistance is also due to the formation of a stable oxide barrier.

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Numerical–experimental investigations on the manufacturing of an aluminium bipolar plate for proton exchange membrane fuel cells by warm hydroforming

Cited by 30 publications

References 22 publications

Elevated temperature forming limit strain diagrams of automotive alloys Al6014-T4 and DP600: A case study

Elevated temperature forming limit strain diagrams of automotive alloys Al6014-T4 and DP600: A case study

Numerical analyses of Manufacturing of an AA8111 Pin-shaped Bipolar Plate by Hot Metal Gas Forming

Effect of Cr content on the corrosion resistance of Ni–Cr–P coatings for PEMFC metallic bipolar plates

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