Development of a Novel Process for Manufacturing of Fuel Cell Bipolar Plates- A Hybrid Internal Pressure Assisted Embossing Process Combined with Mechanical Joining

本研究的目的是探索在协调的内部高压和机械力作用下（a）形成微尺度通道和（B）双层金属键合的可行性。 这种方法的成功将导致成本有效的、集成的、一致的集成双燃料电池双极板的制造，作为需要进一步接合操作的单个双极板的冲压或复合模制的替代方案。 该方法是首先表征在局部压缩载荷条件下薄不锈钢坯料（0.1-0.5 mm）的金属-金属机械结合的可行性。 其次，将使用简单的工具测试使用高内部流体压力和机械力的微尺度通道的形成。 机械键合和微特征变形行为都将使用数值分析代码进行建模和验证，以获得最佳工艺条件。拟议活动的主要社会效益将是通过以可承受的成本使用燃料电池实现近零排放的车辆，提高功率密度，耐用性和高性能。 此外，小型化和集成产品，如热交换器，反应堆，燃料处理器和生物医疗设备，需要复杂的微特征，以实现增加表面积与体积比也将受益于本研究的结果。短期课程和课程模块将开发和整合到现有的设计和制造相关的课程。 这项工作的结果将在工业界、学术界和政府机构之间的研讨会上介绍，以讨论燃料电池制造技术、研究问题和经济性。 该项目期间开发的实验设施和仪器将提供给这些课程的本科生和研究生，供他们进行实验室练习和演示。

The objective of this research is to explore the feasibility of (a) formation of micro-scale channels and (b) bonding of bi-layer metals under coordinated internal high pressure and mechanical force application. The success of this approach will lead to cost-effective, integrated, consistent fabrication of integrated double fuel cell bi-polar plates as an alternative to stamping or composite molding of single bi-polar plates that require further joining operations. The approach is to first characterize the feasibility of metal-to-metal mechanical bonding of thin stainless steel blanks (0.1-0.5 mm) under localized compressive loading conditions. Secondly, formation of micro-scale channels using high internal fluid pressure and mechanical force will be tested using a simple tooling. Both mechanical bonding and micro-feature deformation behaviors will be modeled and validated using numerical analysis codes to obtain optimal process conditions.The main societal benefit of the proposed activity will be vehicles with near-zero-emissions through use of fuel cells at an affordable cost, improved power density, durability, and high performance. In addition, miniaturized and integrated products such as heat exchangers, reactors, fuel processors and bio-medical devices requiring complex micro-features to achieve an increased surface area-to-volume ratio will also benefit from the results of this study.Short courses and course modules will be developed and integrated into the existing design and manufacturing related courses. Results of this work will be presented in workshops among industry, academia and government agencies to discuss fuel cell manufacturing technologies, research issues and economics. Experimental facilities and apparatus developed during the project will be made available to the benefit of undergraduate and graduate students in these courses for lab exercises and demonstrations.