Executive Summary : | Electromagnetic forming of the metallic bipolar plates coated with flow field patterned stack for the proton exchange membrane fuel cell (PEMFC) is a promising alternative for typical graphite bipolar plate fuel cell stacks which compromise 80% of the total volume of PEM fuel cell. The manufacturing cost, volume and reliable methodology of traditional graphite bipolar plates make an initiative to investigate alternative sources for transportation and stationary applications. The continuous research on the exploration of different materials for the bipolar plates made an origin of the lightweight metallic bipolar plate as Stainless steel and Aluminum, which satisfied a greater part of the cost-effectiveness and volume efficiency of PEM fuel cells. The lightweight metallic bipolar plate came with a significant drawbacks of corrosion, chemical compatibility, uneven surfaces, tearing, cracking and non-uniformity in the flow channel of metallic bipolar plates have been investigated. The embossing or etching process was found to be the biggest problem in the mass-production of bipolar plates is that the coating of channels and the ideal plate should be flexible to afford the forming and coating process which is capable to set the technical standards and targets for bipolar plates. According to technical targets (2020) for PEMFC components, United States (U.S.) Department of Energy Efficiency & Renewable Energy standards, the bipolar plates made of the electromagnetic forming process will fulfill standards, and the surface of the coated plate remains of good quality on dimensional accuracy but convex and concave mould environment fundamentally different at ICR should be less than 10 mΩ.cm², corrosion resistance should be less than 1 µA/cm² A sustainable surface coating process must be employed on the designed geometry of the metallic bipolar plate using the vapour deposition process will help to improve the lead-time of developing new anti-corrosion bipolar plates and multi-functional characteristics of high mechanical strength, durability and sustainability because of its high corrosion resistance, high electrical conductivity and high thermal conductivity with relatively low cost and lifespan with easy workability. Current Density (A/cm²), Corrosion Rate (μm/year), and Corrosion Current Density (µA/cm²) has been tested using potentiodynamic polarization corrosion test on anode-sided environment and potentiostatic polarization corrosion test on cathode sided environment for better corrosion resistance. The breaking bonds, wear resistance, weakening of crystalline structures, ductility, porosity, thinner coating and high-temperature resistance will influence the electro-chemical measurement of the surface coating of the metallic bipolar plate lifespan. |