This project consists of a three-year program to progress this technology from proof-of-concept to the fabrication and testing of a full-size bipolar plate test article (TRL 4 - TRL 6)

The program will consist of five major research topics: 1) the optimization of process parameters for ETF and DB fabrication of coated aluminum bipolar plates including optimization of forming and bonding times, development of argon atmosphere processing, developing an understanding of the effect and best practices for preprocessing on diffusion bonding, and the investigation of accelerants for diffusion bonding; 2) the optimization of the dots coating process parameters and incorporation with the ETF process testing multiple potential coating materials including an innovative carbon coating process; 3) development of scale up and cost reduction processes relevant to bipolar plate manufacturing including the fabrication of channel patterned plates, the development of tooling design theory for dies, and the development of DB tracers for enhanced conductivity without additional processing; 4) fabrication of full-scale (> 300 CM2) bipolar plates and demonstration meeting hfto technical targets for bipolar plates; and 5) assessment of durability through fuel cell testing. The major objectives of this project shall be to: 1) develop coated aluminum bipolar plates that meet the DOE cost and technical targets for bipolar plates for heavy-duty applications; 2) repeatable manufacture of bipolar plates at full cell size with relevant feature sizes; and 3) fuel cell accelerated stress testing of subscale cells (~25 CM2) for evaluation of long-term durability and demonstration of fuel cell operation at full cell size (> 300 CM2). The project shall be accomplished in a three-phase program. The final objective of each phase is: phase 1) test data meeting the mechanical property DOE technical targets and technoeconomic analysis indicating the feasibility of the project scope to meet DOE bipolar plate cost targets. Phase 2) corrosion test data meeting the DOE technical targets for electrical properties. Phase 3) accelerated stress testing of subscale cells and demonstration of a full size cell using the test bipolar plates as well as delivery of 6 subscale plates for independent testing and evaluation by the million mile fuel cell truck consortium (M2FCT).