Micro-roll forming of stainless steel bipolar plates for fuel cells

Abeyrathna, Buddhika; Zhang, Peng; Pereira, Michael; Wilkosz, Daniel E.; Weiß, Matthias

doi:10.1016/j.ijhydene.2018.12.013

Cited by 52 publications

(10 citation statements)

References 29 publications

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“…The plane strain stretch will reach failure first and this explains why material failure initiated near profile radius R 1 . The observed inaccuracies in the tool profile may be related to common wear or manufacturing issues and similar observations have been reported in previous studies [13,51]. Overall, the failure mode observed in the micro-stamping trials with material failure initiation in the corner radii suggests that material formability is governed by the plane strain forming limits of the material.…”

Section: The Effect Of the Forming Modesupporting

confidence: 84%

“…Several technologies have been developed to manufacture metal bipolar plates from stainless steel foil. These include micro electrical discharge machining (µEDM) [9], lithography galvanic moulding (LIGA) [10], electrochemical micro-machining (EMM) [11], hydroforming [12], and micro roll forming [13]. The micro-stamping process [14] promises the most economical solution, combined with easy and rapid implementation.…”

Section: Introductionmentioning

confidence: 99%

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Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

Weiß

Zhang

Pereira

et al. 2020

Metals

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This study investigates the effect of grain size and composition on the material properties and forming limits of commercially supplied stainless steel foil for bipolar plate manufacture via tensile, stretch forming and micro-stamping trials. It is shown that in commercially supplied stainless steel the grain size can vary significantly and that ‘size effects’ can be influenced by prior steel processing and composition effects. While the forming limits in micro-stamping appear to be directly linked to the plane strain forming limits of the individual stainless steel alloys, there was a clear effect of the tensile anisotropy. In contrast to previous studies, forming severity and the likelihood of material failure did not increase with a decreasing channel profile radius. This was related to inaccuracies of the forming tool profile shape.

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Section: The Effect Of the Forming Modesupporting

confidence: 84%

Section: Introductionmentioning

confidence: 99%

Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

Weiß

Zhang

Pereira

et al. 2020

Metals

Self Cite

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“…Metals offer numerous benefits to the BPP applications and some of the benefits include generally minimal cost, high strength, simplicity of production, and corrosion resistance. 40,41 Metallic BPP can be effortlessly manufactured for complex shape applications and can give a huge improvement in the energy component innovation. 40 Stainless steels are high-strength corrosion resistance materials utilized in corrosive conditions in light of a promising combination of mechanical properties, corrosion resistance, and cost viability when contrasted with other materials for BPP application.…”

Section: Stainless Steel As Bipolar Plates Materialsmentioning

confidence: 99%

“…40,41 Metallic BPP can be effortlessly manufactured for complex shape applications and can give a huge improvement in the energy component innovation. 40 Stainless steels are high-strength corrosion resistance materials utilized in corrosive conditions in light of a promising combination of mechanical properties, corrosion resistance, and cost viability when contrasted with other materials for BPP application. 42,43 The fabrication process of the stainless steel can influence the corrosion behavior of the material and the synthetic organization of the stainless steel decides by and large their applications as BPP materials.…”

Section: Stainless Steel As Bipolar Plates Materialsmentioning

confidence: 99%

A review of bipolar plates materials and graphene coating degradation mechanism in proton exchange membrane fuel cell

Okonkwo

Emori

Uzoma

et al. 2021

Intl J of Energy Research

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“…However, up to now, it has not been possible to use this process for complete bipolar plate structures because it is just feasible for continuous geometries and not for closed structures. Furthermore, the plateaus on the top and the bottom of the formed geometry are still not even, which is unfavourable for further operations like welding and assembly [11,12]. In order to cope with these limitations this new roll forming strategy was developed and used for the first time to produce channels with industrial relevant scaled geometries for bipolar plates by forming 0.1 mm thick 316L (1.4404) metal foils.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing of Metallic Bipolar Plate Channels by Rolling

Bauer

Härtel

Awiszus

2019

JMMP

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Producing metallic bipolar plates for Proton Exchange Membrane (PEM) fuel cells by forming is still a topic of research. So far, it has mainly been applied for small batches, but it offers substantial advantages regarding both costs and installation space compared to the established graphite based solutions. One new possibility for an efficient manufacturing process of these metallic bipolar plates is the forming by rolling. For the first time, this technology was used for relevant industrial scale channel geometries. By the use of an experimental rolling mill, 0.1 mm thick 316L (1.4404) stainless steel foils were roll-formed to achieve previously designed channel geometries within one rolling pass. The conducted experiments show promising results regarding the forming accuracy and the shape of the channel cross-sections. With the aim for a proof of concept in the beginning and a subsequent optimization of the process, a numerical simulation was set up prior to the real experiments and later calibrated with the experimental forming results. This calibrated model was used for further improvements of the process with the objective at reducing wrinkles and distortion. The investigation of this new process method for the manufacturing of metallic bipolar plates shows enormous potential and can lead to a more efficient and cheaper production.

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Micro-roll forming of stainless steel bipolar plates for fuel cells

Cited by 52 publications

References 29 publications

Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

A review of bipolar plates materials and graphene coating degradation mechanism in proton exchange membrane fuel cell

Manufacturing of Metallic Bipolar Plate Channels by Rolling

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