Fuel Pressure Distribution as a Criterion for the Bipolar Plate Geometry Optimization in PEM Fuel Cells,Modeling and Experiment

In this study the pressure distribution homogeneity on the catalytic surface is found to provide a simple and reliable fuel flow parameter that can be used to optimize the bipolar plate geometry and the PEM fuel cell performance. Finite element commercial ANSYS software was used to determine the fuel velocity, pressure and mass distribution on eight different bipolar plate geometries. These geometries were also fabricated and characterized experimentally in order to establish a correlation between the power densities with the fuel flow parameters obtained from the simulations. The results show that a highly uniform pressure distribution of the fuel in the bipolar plate is necessary to obtain higher power densities. Inversely, non‐homogeneous pressure distributions lead to lower power densities. Additionally, the measured power density increases when the geometry dependent effective catalytic surface area increases. These results are interesting since they provide an optimization methodology for PEM fuel cells that simplifies and reduces computing requirements, experimentation and manufacturing time.     

Evaluation of Ni‐Mo and Ni‐Mo‐P Electroplated Coatings on Stainless Steel for PEM Fuel Cells Bipolar Plates

Stainless steel bipolar plates (BPPs) are the preferred choice for proton exchange membrane fuel cells (PEMFCs); however, a surface coating is needed to minimize contact resistance and corrosion. In this paper, Ni–Mo and Ni–Mo–P coatings were electroplated on stainless steel BPPs and investigated by XRD, SEM/EDX, AFM and contact angle measurements. The performance of the BPPs was studied by corrosion and conduction tests and by measuring their interfacial contact resistances (ICRs) ex situ in a PEMFC set‐up at varying clamping pressure, applied current and temperature. The results revealed that the applied coatings significantly reduce the ICR and corrosion rate of stainless steel BPP. All the coatings presented stable performance and the coatings electroplated at 100 mA cm⁻² showed even lower ICR than graphite. The excellent properties of the coatings compared to native oxide film of the bare stainless steel are due to their higher contact angle, crystallinity and roughness, improving hydrophobicity and electrical conductivity. Hence, the electroplated coatings investigated in this study have promising properties for stainless steel BPPs and are potentially good alternatives for the graphite BPP in PEMFC.     

Metallic Bipolar Plates for High Temperature Polymer Electrolyte Membrane Fuel Cells

High temperature polymer membrane fuel cells (HTPEMFCs) are promising devices for future mobile applications. To minimize phosphoric acid migration from the membranes and to reduce the total stack weight and size metallic bipolar plates are a promising alternative. So far only very few published results are available on the use of metallic bipolar plates in HTPEMFCs. During this work a single test cell was equipped with metallic endplates to investigate the possibility of using metallic bipolar plates in HTPEMFC stacks. Furthermore we tried to simulate the environments present in an HTPEMFC by furnace exposures in an attempt to develop a simplified test method for accelerated corrosion of bipolar plate materials. It was found that the performance of the HTPEM test cell decreased by about 15 µV h⁻¹. More corrosion products were seen on the cathode side samples, whereas on the anode side sample the corrosion attack of the steel was more severe. These results were successfully replicated in simulated furnace experiments.     

Expanded Graphite–Epoxy–Flexible Silica Composite Bipolar Plates for PEM Fuel Cells

Silica impregnated expanded graphite–epoxy composites are developed as bipolar plates for proton exchange membrane (PEM) fuel cells. These composite plates were prepared by solution impregnation, followed by compression molding and curing. Mechanical properties, electrical conductivities, corrosion resistance, and contact angles were determined as a function of impregnated content. The plates show high flexural strength with 5% methyltrimethoxysilane (MTMS) addition (20 MPa) and in‐plane conductivity of 131 S cm⁻¹ that meet the DOE target (>100 S cm⁻¹). Corrosion current values as low as 1.09 μA cm⁻² were obtained. The contact angle was found to be 80°. Power density of 1 W cm⁻² was achieved with custom made expanded graphite–polymer composite plates. High efficiency values were obtained at low current regions.     

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

Aluminum bipolar plates that can replace graphite bipolar plates for PEM fuel cells are made by applying a semi‐solid forging process. A semi‐solid slurry is made using electromagnetic stirring (EMS), and the resulting slurry is injected into a forging die attached to a 200 ton hydraulic press. The slurry is then compressed with a punch, flowed into a die cavity, and solidified into the bipolar plate form. A356 (cast Al alloy), A6061 (wrought Al alloy), and A1100 (pure Al) are used to make the plates. Titanium nitride (TiN) coating is deposited on the aluminum bipolar plates. An atomic force microscope (AFM) is used to measure the surface roughness of the plates. TiN coated A356 and A1100 plates have a surface roughness of R_a < 1.2 μm. The plate thickness is 1.2 mm. The active area of the channel is 70 mm × 70 mm, with a depth and width of 0.3 and 1.0 mm, respectively. The three TiN‐coated aluminum plates are combined with a unit cell for a performance test. Our results show that a current density value of 473 mA cm^–2 (about 41% of the current density value of commercial graphite plates) can be obtained.     

A Novel Design of Wave‐Like PEMFC Stack with Undulate MEAs and Perforated Bipolar Plates

Commercialisation of proton exchange membrane fuel cell (PEMFC) technology depends on high volumetric power density and specific power for a given cost. In the present study, a novel wave‐like architecture for PEMFC stack based on undulate membrane electrode assembles (MEAs) and perforated bipolar plates (PBPs) was presented. Different from conventional plate‐and‐frame architecture, this design increased active area and achieved higher volumetric power density due to undulate MEAs. Moreover, perforated sheet metal was used as bipolar plates so that it could improve specific power. A single cell was designed and fabricated in house to evaluate the performance of the novel architecture stack. Stamped PBPs with open rate of 28.26% and hot pressed 5‐layer undulate MEAs with Nafion® 112 were adopted. The results indicated that the peak volumetric power density and specific power are 2,715.94 W L^–1 and 2,157.86 W kg^–1, respectively, while they are 2,151.28 W L^–1 and 1,709.22 W kg^–1 at the output voltage of 0.6 V. This study may propose a possible means to meet the DOE's 2010 technical target that volumetric power density is 2,000 W L^–1 and specific power is 2,000 W kg^–1 for stack.     

Synergistic Effects of Carbon Fillers of Phenolic Resin Based Composite Bipolar Plates on the Performance of PEM Fuel Cell

The most essential and costly component of polymer electrolyte membrane fuel cells is the bipolar plate. The production of suitable composite bipolar plates for polymer electrolyte membrane fuel cell with good mechanical properties and high electrical conductivity is scientifically and technically very challenging. This paper reports the development of composite bipolar plates using exfoliated graphite, carbon black, and graphite powder in resole‐typed phenol formaldehyde. The exfoliated graphite with maximum exfoliated volume of 570 ± 10 mL g⁻¹ used in this study was prepared by microwave irradiation of chemically intercalated natural flake graphite in a few minutes. The composite plates were prepared by varying exfoliated graphite content from 10 to 35 wt.% in phenolic resin along with fixed weight percentage of carbon black (5 wt.%) and graphite powder (3 wt.%) by compression molding. The composite plates with filler weight percentage of 35/5/3/exfoliated graphite/carbon black/graphite powder offer in‐plane and trough‐plane electrical conductivities of 374.42 and 97.32 S cm⁻¹, bulk density 1.58 g cm⁻³, compressive strength 70.43 MPa, flexural strength 61.82 MPa, storage modulus 10.25 GPa, microhardness 73.23 HV and water absorption 0.22%. Further, I–V characteristics notify that exfoliated graphite/carbon black/graphite powder/resin composite bipolar plates in unit fuel cell shows better cell performance compared exfoliated graphite/resin composite bipolar plates. The composite plates own desired mechanical properties with low bulk density, high electrical conductivity, and good thermal stability as per the U.S. department of energy targets at low filler concentration and can be used as bipolar plates for proton exchange membrane fuel cells.     

Effects of Potential on Corrosion Behavior of Uncoated SS316L Bipolar Plate in Simulated PEM Fuel Cell Cathode Environment

The effect of potential on the corrosion behavior of uncoated stainless steel SS316L as bipolar plate material in proton exchange membrane (PEM) fuel cell cathode environment is studied. Electrochemical methods, X‐ray photoelectron spectroscopy, scanning electron microscope are employed to characterize the corrosion behavior of SS316L at different polarization potentials in PEM fuel cell cathode environment. The results show that the corrosion current density of SS316L increases with the increase of polarization potential significantly. When the potential is higher than 0.7 V versus SCE, severe corrosion occurs on SS316L. The work also shed light on the corrosion mechanisms of SS316L at different potential in the PEM fuel cell cathode environment.     

Advances in Mixed‐Reactant Fuel Cells

The mixed‐reactant fuel cell (MRFC) is a new concept, in which a mixture of aqueous fuel and gaseous oxygen (or air) flows directly through a porous anode‐electrolyte‐cathode structure or through a strip‐cell with an anode‐electrolyte‐cathode configuration. These structures can be single cells or parallel stacks of cells and may be in a planar, tubular or any other geometry. Selectivity in the electrocatalysts for MRFCs is mandatory to minimize mixed‐potential at the electrodes, which otherwise would reduce the available cell voltage and compromise the fuel efficiency. MRFC offers a cost effective solution in fuel cell design, since there is no need for gas‐tight structure within the stack and, as a consequence, considerable reduction in sealing, manifolding and reactants delivery structure is possible. In recent years, significant advances have been made in MRFCs, using methanol as a fuel. This paper reviews the status of mixed reactant fuel cells and reports some recent experimental data for methanol fuel cell systems.     

Evaluation of a Non‐sealed Solid Oxide Fuel Cell Stack with Cells Embedded in Plane Configuration

A non‐sealed solid oxide fuel cell stack with cells embedded in plane configuration was fabricated and operated successfully in a box‐like stainless‐steel chamber. For a two‐cell stack, it demonstrated an open circuit voltage (OCV) of 2.13 V and a maximum power output of 569 mW at the flow rate of 67 sccm CH₄ and 33 sccm O₂. A fuel utilization of 4.16% was obtained. The cell performance was dominated by two different mechanisms, the polarization of the cathode at low current and the concentration polarization of the anode at high current. Finally, a scaled‐up stack with six cells in series generated an OCV of 6.4 V and a maximum power output of 8.18 W.     

Detection of Liquid Water in PEM Fuel Cells' Channels: Design and Validation of a Microsensor

Suitable water management is a critical issue to reach the full potential of PEM fuel cells: whereas the membrane must be hydrated enough, liquid droplets formed by water in excess can block the flow in the gas distribution channels and hinder the fuel cell performance. In order to detect the presence of droplets in cathode flow channel, an electrochemical sensor has been developed and tested in a dedicated emulation cell. It is based on the widely used principle of two‐electrode cells for conductivity measurements; the collected signal is converted to impedance values. The sensor, mounted in a gas flow channel grooved in a graphite plate, reacts to the passage of water droplets, either being injected into the continuous air stream or produced by condensation of humidified air at the graphite plate. The time variation of the electrical impedance could be correlated to the observations allowed by the high‐speed digital camera. Water droplets separated from each other by less than a second can be distinguished by the sensor, which is of a sufficient rapidity.     

A Promising Alternative to PEMFC Graphite Bipolar Plates: Surface Modified Type 304 Stainless Steel with TiN Nanoparticles and Elastic Styrene Butadiene Rubber Particles

In order to utilise inexpensive bipolar plates for proton exchange membrane fuel cells (PEMFC), a surface modification with TiN nanoparticles and elastic styrene butadiene rubber (SBR) particles has been applied to the most widely commercialised stainless steel of type 304 which did not satisfy the required properties in the bare form. The electro‐conducting agglomerates were electrophoretically deposited on the stainless steel bipolar plates. The surface modification greatly improved the corrosion resistance of the stainless steel as well as the interfacial contact resistance (ICR). As a result, the cell performance was significantly enhanced and become comparable to that with graphite bipolar plate during operation for 1,000 h. Ac‐impedance results indicated that the TiN–SBR coating was effective not only in reducing the ICR but also in retaining the resistance low throughout the operation. The hydrophobic character of the TiN–SBR coating on the stainless steel bipolar plates, which facilitated the removal of the formed water in the cathode side during the single cell operation, is also responsible for the enhanced cell performance. Therefore, the type 304 stainless steel bipolar plate modified with the electro‐conducting nanosized TiN – elastic SBR particles is suggested to be a promising substituent for the PEMFC graphite bipolar plate.     

Effect of Serpentine Multi‐pass Flow Field Channel Orientation in the Liquid Water Distributions and Cell Performance

A commercial 50 cm² polymer electrolyte membrane (PEM) fuel cell with serpentine flow fields was operated at 2.0 bar and 60 °C with two orientations of the flow field channels with respect to gravity, i.e. horizontal and vertical channels. A 3 × 3 test matrix of anode and cathode reactants relative humidity was used for the performance assessment of the cell in both orientations. The cell performance and operating data, including cell voltage and resistance, were measured, and neutron radiographs were recorded during the entire operation in order to gain knowledge of the liquid water distributions within the cell for both orientations. A quantitative analysis of the results is presented in this work, comparing the cell operation for both flow field orientations. It is observed that the configuration with horizontal cathode flow field channels presents a better cell performance, and less amount of liquid water blocking the flow field channels. Thus, the results show that the selection of the cell orientation has an influence on the final performance, and it is therefore, a design parameter to be considered for a real application. The differences in the cell water content are quantitatively analyzed and discussed.     

The Operation of HT‐PEM Fuel Cells Coupled to Lithium Ion Batteries in a Fleet of Light Passenger Vehicles

High temperature polymer electrolyte membrane (HT‐PEM) fuel cells offer some advantages over their low temperature equivalent, but there have been relatively few reports into their use in vehicles. This paper describes the power train design and operation of a fleet of Microcab H2EV vehicles. The power train consisted of a HT‐PEM fuel cell coupled via a DC/DC convertor to a lithium iron phosphate traction battery, which was then connected to two Lynch motors. The integration and operation of all the major power train components is described. Also described here is the vehicle control unit that uses digital and analog communications to provide overall management of the vehicle. Details are given of all the safety systems designed into the vehicle. Some data describing the performance of the H2EV power‐train during typical drive cycles is presented, which shows that the system was functional. It is concluded that HT‐PEM fuel cell light vehicles are viable, but the heating and cooling time of the fuel cell needs to be significantly reduced.     

Performance Assessment of a Combined PEM Fuel Cell and Triple‐Effect Absorption Cooling System for Cogeneration Applications

In this paper, a parametric study of a combined proton exchange membrane (PEM) fuel cell and triple‐effect absorption cooling system (TEACS) is undertaken to investigate the effect of different operating conditions and system parameters on the COPs, efficiency of the fuel cell and the integrated system's overall utilisation factor. It is found that the fuel cell efficiency increases from 40% to 44.5% as the operating temperature of the fuel cell increases. However, as the fuel cell's temperature and current density increase, the COPs decrease from 2.4 to 0.9 as a result of the increase in the energy output of the fuel cell ranging from 7.4 to 10.7 kW. The efficiency of the fuel cell decreases from 41% to 32% with an increase in both fuel cell's current density and membrane thickness. The overall utilisation factor of the integrated system decreases from 84% to 35% with an increase in the current density and molar flow rate. Finally, this study reveals that the present integrated PEM fuel cell unit with a TEACS can be considered as an attractive and environmentally benign option for cogeneration purposes in sustainable buildings.     

Numerical and Experimental Verification of the Polymer Electrolyte Fuel Cell Performances Enhanced by Under‐Rib Convection

Understanding the current density distributions in polymer electrolyte fuel cells (PEFCs) is crucial for designing cell components, such as the flow field of bipolar plates. A new serpentine flow field equipped with sub‐channels and by‐passes (SFFSB) was numerically and experimentally confirmed to enhance the reactant transport rates and liquid removal efficiency compared with a conventional advanced serpentine flow field (CASFF). Consequently, the maximum current and the power densities of the SFFSB were increased due to the promotion of under‐rib convection. In this study, current density distributions are measured under transient conditions to verify the PEFC performances enhanced by under‐rib convection. The current density distributions of the SFFSB are compared with those of the CASFF. The results show that the SFFSB has a higher local current density and a more uniform distribution than the CASFF, therefore, the PEFC performances with the new flow field of SFFSB is enhanced by the better current density distributions.     

Corrosion Investigation of Chromium Nitride and Chromium Carbide Coatings for PEM Fuel Cell Bipolar Plates in Simulated Cathode Condition

Transition metals nitrides and carbides are used as coatings on bipolar plates for proton exchange membrane fuel cells (PEMFCs) due to their suitable electrical conductivity and corrosion resistance. Chromium electroplated AISI 316L stainless steel bipolar plates were treated by plasma nitriding and solid carburizing to form chromium nitride and chromium carbide, respectively. The presence of CrN/Cr₂N and Cr₇C₃/Cr₂₃C₆ was verified by X‐ray diffractometry (XRD) in chromium nitride and chromium carbide coatings, respectively. The corrosion behavior of coatings was investigated by potentiodynamic polarization, potentiostatic polarization and electrochemical impedance spectroscopy (EIS) in simulated cathode condition. Coated samples showed better corrosion behavior than untreated bare sample. EIS results indicated decrease in corrosion current density after 500 hours, however coatings acted as barrier against solution access to substrate. Corrosion current densities of coatings were close to targets of United Stated department of energy (DOE).     

Development and Characterisation of Electrically Conductive Polymeric‐Based Blends for Proton Exchange Membrane Fuel Cell Bipolar Plates

The main objective of this work was to develop films with controlled dimensions for proton exchange membrane fuel cell (PEMFC) bipolar plates (BPPs) using the twin‐screw extrusion process. These films consisted of a low‐viscosity polyethylene terephthalate (PET) in which a mixture of high specific surface area carbon black (CB) and synthetic flake graphite (GR) were dispersed. A third conductive additive, consisting of silver‐coated glass particles (SCG) or multi‐walled carbon nanotubes (MWCNT), was also added at a low concentration (5 wt.‐%) in order to study its synergistic effect on the PET‐based blend electrical conductivity. As the developed blends had to meet properties suitable for PEMFC bipolar plate applications, they were characterised for their electrical through‐plane resistivity, mechanical properties and oxygen permeability. Through‐plane electrical resistivity of about 0.3 Ω·cm and oxygen permeation rate of 3.5 × 10^–8 cc cm^–2 s^–1 were obtained for only 30 wt.‐% of a 60:40 mixture of CB/GR conductive additives. Although the substitution of 5 wt.‐% of CB/GR by the same amount of MWCNT had no significant effect on BPPs' electrical resistivity, it helped to improve their mechanical properties and especially their oxygen permeation, which was decreased from 3.5 × 10^–8 cc cm^–2 s^–1 to around 0.6 × 10^–8 cc cm^–2 s^–1.     

Non–Pt Catalyst Layer Operation in a PEM Fuel Cell: A Variable‐thickness Regime

A recently pubilshed experimental polarization curve of a PEM fuel cell with the non–Pt cathode catalyst layer (CCL) exhibits unusual feature: in the region of small current densities, the curve is close to linear. We report a model for the CCL performance which explains this effect. The model includes finite rate of the oxygen adsorption on the catalyst surface. Qualitatively, due to a very high exchange current density of the non–Pt catalyst, the ORR rate close to the membrane is determined by the potential–independent oxygen adsorption rate. This leads to a specific regime of the CCL operation, when only part of the CCL thickness contributes to current production, while the rest part is completely inactive. With the growth of the cell current, the active part increases in width, while the inactive part shrinks. The resulting polarization curve appears to be close to linear.     

Effect of Contact Method between Interconnects and Electrodes on Area Specific Resistance in Planar Solid Oxide Fuel Cells

In this work, interconnect/electrode sheet/interconnect sandwiches are assembled by designing interfacial contact between interconnects and electrodes for planar solid oxide fuel cells (SOFCs). Their area specific resistance (ASR) values of different contact methods under isothermal oxidation and thermal cycling are recorded by four‐point method. The ASR of SUS430/Ni–YSZ/SUS430 anode sandwich with NiO current collecting layer is close to that of anode sandwich without NiO current collecting layer during isothermal operation, but smaller and more stable during thermal cycling. Meanwhile, the lowest ASR is obtained in SUS430/LSM–YSZ/SUS430 cathode sandwich with LSM coated interconnect and LSM current collecting layer among various contact methods between interconnects and cathodes, and remains constant under isothermal oxidation and thermal cycling. Contact resistance between cathodes and interconnects is the main source of the SOFC stack resistance. A real stack with three anode‐supported cells is assembled and tested under thermal cycling to verify the effect of different contact methods between interconnects and electrodes on performance of stack repeating unit. The degradation rate and ASR values of repeating unit inside the stack indicate that the contact between LSM coated interconnect and LSM current collecting layer on cathode side is the optimized contact.