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Investigations on the Effect of Manufacturing on the Contact Resistance Behavior of Metallic Bipolar Plates for Polymer Electrolyte Membrane Fuel Cells

机译：制备对聚合物电解质膜燃料电池金属双极板接触电阻行为影响的研究

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Polymer electrolyte membrane fuel cells (PEMFCs) have emerged as a strong and promising candidate to replace internal combustion engines (ICE) due their high efficiency, high power density and near-zero hazardous emissions. However, their commercialization waits for solutions to bring about significant cost-reductions and significant durability for given power densities. Bipolar plate (BPP) with its multi-faceted functions is one of the essential components of the PEMFC stacks. Stainless steel alloys are considered promising materials of choice for bipolar plate (BPP) applications in polymer electrolyte membrane fuel cells (PEMFC) due to their relatively low cost and commercial availability in thin sheets. Stainless steel materials build a protective passive metal oxide layer on their surface against corrosion attack. This passive layer does not demonstrate good electrical conductivity and increases interfacial electric contact resistance (ICR) between BPP and gas diffusion layer GDL in PEMFC. Lower ICR values are desired to reduce parasitic power losses and increase current density in order to improve efficiency and power density of PEMFC. This study aimed to bring about a broader understanding of manufacturing effects on the BPP contact resistance. In first stage, BPP samples manufactured with stamping and hydroforming under different process conditions were tested for their electrical contact resistance characteristics to reveal the effect of manufacturing type and conditions. As a general conclusion, stamped BPPs showed higher contact conductivity than the hydroformed BPPs. Moreover, pressure in hydroforming and geometry had significant effects on the contact resistance behavior of BPPs. Short term corrosion exposure was found to decrease the contact resistance of bipolar plates. Results also indicated that contact resistance values of uncoated stainless steel BPPs are significantly higher than the respective target set by U.S. Department of Energy. Proper coating or surface treatments were found to be necessary to satisfy the requirements. In the second stage, physical vapor deposition technique was used to coat bipolar plates with CrN, TiN and ZrN coatings at 0.1, 0.5 and 1 μm coating thicknesses. Effects of different coatings and coating thickness parameters were studied as manufactured BPPs. Interfacial contact resistance tests indicated that CrN coating increased the contact resistance of the samples. 1 µm TiN coated samples showed the best performance in terms of low ICR; however, ICR increased dramatically after short term exposure to corrosion under PEMFC working conditions. ZrN coating also improved conductivity of the SS316L BPP samples. It was found that the effect of coating material and coating thickness was significant whereas the manufacturing method and BPP channel size slightly affected the ICR of the metallic BPP samples. Finally, effect of process sequence on coated BPPs was investigated. In terms of ICR, BPP samples which were coated prior to forming exhibited similar or even better performance than coated after forming samples. Thus, continuous coating of unformed stripes, then, applying forming process seemed to be favorable and worth further investigation in the quest of making cost effective BPPs for mass production of PEMFC.
机译：高分子电解质膜燃料电池（PEMFC）由于其高效，高功率密度和接近零的有害排放物而成为替代内燃机（ICE）的有力和有希望的候选者。但是，他们的商业化正在等待解决方案，以在给定功率密度的情况下显着降低成本并显着提高耐用性。具有多方面功能的双极板（BPP）是PEMFC叠层的重要组成部分之一。不锈钢合金被认为是聚合物电解质膜燃料电池（PEMFC）中双极板（BPP）应用的有前途的选择材料，因为它们的成本相对较低，并且在薄板中可商购。不锈钢材料在其表面上形成保护性的钝化金属氧化物层，以防止腐蚀。该无源层没有表现出良好的导电性，并增加了BMFC与PEMFC中气体扩散层GDL之间的界面电接触电阻（ICR）。需要较低的ICR值以减少寄生功率损耗并增加电流密度，以提高PEMFC的效率和功率密度。这项研究旨在使人们对BPP接触电阻的制造效果有更广泛的了解。在第一阶段，测试在不同工艺条件下通过冲压和液压成型制造的BPP样品的电接触电阻特性，以揭示制造类型和条件的影响。总的来说，冲压成型的BPP的接触电导率比液压成型的BPP高。此外，液压成形中的压力和几何形状对BPP的接触电阻行为具有重要影响。发现短期腐蚀暴露会降低双极板的接触电阻。结果还表明，未涂覆的不锈钢BPP的接触电阻值明显高于美国能源部设定的目标。发现必须进行适当的涂层或表面处理才能满足要求。在第二阶段中，使用物理气相沉积技术以0.1、0.5和1μm的涂层厚度在CrN，TiN和ZrN涂层上涂覆双极板。研究了不同涂层和涂层厚度参数对人造BPP的影响。界面接触电阻测试表明，CrN涂层增加了样品的接触电阻。 1 µm TiN涂层样品在低ICR方面表现出最佳性能；但是，在PEMFC工作条件下短期暴露于腐蚀后，ICR急剧增加。 ZrN涂层还改善了SS316L BPP样品的电导率。发现涂层材料和涂层厚度的影响是显着的，而制造方法和BPP通道尺寸对金属BPP样品的ICR影响很小。最后，研究了工艺顺序对包衣的BPP的影响。就ICR而言，在成型前涂覆的BPP样品表现出与成型后涂覆相似或什至更好的性能。因此，连续涂覆未形成的条带，然后施加成形工艺似乎是有利的，并且在寻求制造用于批量生产PEMFC的具有成本效益的BPP方面值得进一步研究。

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    Turan Cabir;

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