Fabrication by vacuum die casting and simulation of aluminum bipolar plates with micro-channels on both sides for proton exchange membrane (PEM) fuel cells

► Aluminum bipolar plates have been fabricated using vacuum die casting. ► Optimal melt temperature for good formability and mechanical properties are 700 °C. ► The higher the injection speed of the high-speed region, the more effective the formability. ► Vacuum die casting is more beneficial in terms of formability than is die casting. ► Vickers hardness of bipolar plate is about 100 Hv which increases to 110 Hv after T6.