Simulation and in situ measurement of stress distribution in a polymer electrolyte membrane fuel cell stack

A critical parameter for PEM fuel cell's electric contact is the nominal clamping pressure. Predicting the mechanical behavior of all components in a fuel cell stack is a very complex task due to the diversity of materials properties. Prior to the integration of a 3 kW PEMFC power plant, a numerical simulation was performed in order to obtain the mechanical stress distribution for two of the most pressure sensitive components of the stack: the membrane, and the graphite plates. The stress distribution of the above mentioned components was numerically simulated by finite element analysis and the stress magnitude for the membrane was confirmed using pressure films. Stress values were found within the elastic zone which guarantees mechanical integrity of fuel cell components. These low stress levels particularly for the membrane will allow prolonging the life and integrity of the fuel cell stack according to its design specifications.