Study on Hydroforming Mechanism of Titanium Bipolar Plates for Hydrogen Fuel Cells

doi:10.12096/j.2096-4528.pgt.23127

Abstract

Abstract:

Objectives Due to the anisotropic nature of titanium bipolar plates, their manufacturing process is highly challenging. While hydroforming has been commercially applied in bipolar plate production abroad, research in this field remains limited domestically. In order to reveal the control relationship between hydroforming parameters and quality in bipolar plate fabrication, it is essential to investigate the hydroforming mechanism of titanium bipolar plates. Methods This study focuses on the hydroforming process of titanium bipolar plates with a serpentine flow field. It analyzes the mechanical properties of the bipolar plates during the hydroforming process and explores the effects of key parameters, including die fillet radius, flow channel width, flow channel depth, sheet thickness, and hydraulic pressure, on the final forming quality. Results The stress distribution in the corner regions of the serpentine flow channels is highly complex, making these areas most susceptible to fracture. Increasing the die fillet radius effectively reduces the thinning rate, with a recommended minimum radius of 0.2 mm. Increasing flow channel depth significantly worsens thinning, and the depth should not exceed 0.28 mm. When the flow channel width equals the rib width, the thinning rate reaches its minimum. Hydraulic pressure has a greater impact on thinning before the plate contacts the die bottom but its impact diminishes afterward. Additionally, as the plate thickness increases, the overall forming quality deteriorates. Conclusions The coordinated design of hydroforming parameters and structural parameters is critical for ensuring the forming quality of bipolar plates. These findings provide a theoretical foundation for the design and optimization of metal bipolar plate hydroforming process.

Key words: hydrogen fuel cell, proton exchange membrane fuel cell (PEMFC), metal bipolar plate, hydroforming, thinning rate, stress distribution

CLC Number:

TK 91

Jie ZHANG, Ruichuan WANG. Study on Hydroforming Mechanism of Titanium Bipolar Plates for Hydrogen Fuel Cells[J]. Power Generation Technology, 2025, 46(4): 727-736.

Figures/Tables 13

Fig. 1 Hydroforming structure of bipolar plate

Tab. 1 Structural parameters of bipolar plate

参数	数值
板料厚度d/mm	0.1
模具周期长度L_d/mm	2
模具肋宽S_d/mm	0.6
模具深度h_d/mm	0.30
模具外倒角半径R_d/mm	0.2
拔模角/（°）	0

Fig. 2 Simulation model of bipolar plate hydroforming

Fig. 3 Hydraulic pressure loading curve

Fig. 4 Stress variation of titanium bipolar plate during hydroforming process

Fig. 5 Stress variation of bipolar plate with loading time

Fig. 6 Residual stress distribution of titanium bipolar plate after hydroforming

Fig. 7 Equivalent plastic strain and thickness variation of bipolar plate

Fig. 8 Effect of fillet radius on forming quality of bipolar plate

Fig. 9 Effect of flow channel depth on forming quality of bipolar plate

Fig. 10 Effect of flow channel width on forming quality of bipolar plate

Fig. 11 Effect of sheet thickness on forming quality of bipolar plate

Fig. 12 Effect of hydraulic pressure on forming quality of bipolar plate

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