Simulation and fabrication of micro-scaled flow channels for metallic bipolar plates by the electrochemical micro-machining process

In order to take better advantage of metallic bipolar plates for producing metallic fuel cells and make it a feasible technology, it is essential that we have an efficient and cost effective fabrication process for creating micro-scaled flow channels. In this study, an electrochemical micro-machining (EMM) process is developed. In order to have better process control a finite element analysis is employed to ensure machine tool platform rigidity; an electric field analysis is applied for the electrode design; and an electrolytic flow analysis is carried out for the fixture design and the selection of the operational parameter. Finally, flow channels measuring 200 μm in depth and 500 μm in width are fabricated on SS316 stainless steel sheets measuring 50 mm × 0.6 mm thick.