Fabrication of metallic bipolar plate for proton exchange membrane fuel cells by using polymer powder medium based flexible forming

Flexible forming process-polymer powder medium based flexible forming (PPFF) is presented in this research. The metallic bipolar plate (BPP) for a proton exchange membrane (PEM) fuel cell, with a micro-scale flow channel on its surface, is formed using rigid die forming and PPFF process, respectively. Pure copper C1100 (with a thickness of 0.1 mm), annealed at 450 °C for 1 h in vacuum condition, is selected as blank material. The forming experiments are carried out at room temperature in dry friction condition. By comparing the limit forming depth, fracture topography, section wall thickness distribution and surface forming quality of micro-scale flow channels between rigid die forming and PPFF process, it reveals that PPFF process could be developed as a feasible technique to fabricate the bipolar plates of PEM fuel cells. The PPFF process has the following advantages: greater forming depth, more uniform wall thickness distribution, and low cost of the die.