New electroplated aluminum bipolar plate for PEM fuel cell

• Published in: Journal of power sources 2008-02, Vol.177 (1), p.131-136
• Main Authors: El-Enin, Sanaa A. Abo, Abdel-Salam, Omar E., El-Abd, Hammam, Amin, Ashraf M.
• Format: Article
• Language: English
• Subjects: Applied sciences; Bipolar plate; Electroplating; Energy; Energy. Thermal use of fuels; Equipments for energy generation and conversion: thermal, electrical, mechanical energy, etc; Exact sciences and technology; Fuel cell; Fuel cells; PEM
• ISSN: 0378-7753; 1873-2755
• DOI: 10.1016/j.jpowsour.2007.11.042

Further improvement in the performance of the polymer electrolyte membrane fuel cells as a power source for automotive applications may be achieved by the use of a new material in the manufacture of the bipolar plate. Several nickel alloys were applied on the aluminum substrate, the use of aluminum as a bipolar plate instead of graphite is to reduce the bipolar plate cost and weight and the ease of machining. The electroplated nickel alloys on aluminum substrate produced a new metallic bipolar plate for PEM fuel cell with a higher efficiency and longer lifetime than the graphite bipolar plate due to its higher electrical conductivity and its lower corrosion rate. Different pretreatment methods were tested; the optimum method for pretreatment consists of dipping the specimen in a 12.5% NaOH for 3 min followed by electroless zinc plating for 2 min, then the specimen is dipped quickly in the electroplating bath after rinsing with distilled water. The produced electroplate was tested with different measurement techniques, chosen based on the requirement for a PEM fuel cell bipolar plate, including X-ray diffraction, EDAX, SEM, corrosion resistance, thickness measurement, microhardness, and electrical conductivity.