Slide 1: High-Velocity and High-speed Manufacturing Method and Manufacturing Cost Analysis for PEM FC Applications
High-Velocity and High-speed Manufacturing Method and Manufacturing Cost Analysis for PEM FC Applications Fuel Cell Seminar November 16-19, 2015
Slide 2: About Sandvik
About Sandvik Sandvik is a developer and producer of advanced stainless steels, special alloys, titanium and other high-performance materials.
Slide 3: About AP&T
About AP&T AP&T is a global supplier and market leader for heat exchanger plates. In general, AP&T provides the sheet metal industries worldwide with complete production systems as well as with stand-alone presses, automation and tooling.
Slide 4: About Cell Impact
About Cell Impact Cell Impact is a global supplier to the manufacturing industry of reliable, integrable and cutting-edge high- velocity units that result in high- quality production, greater effectiveness and capabilities that surpass those of conventional machine tooling.
Slide 5: Alternative Process
The process 316L, t=100/(75) µm 316L, t=100/(75) µm Coil Flattening PVD Coating Alternative Process Stamping & cutting 7 progressive steps Stamping & cutting Typical Process 3 steps Laser welding Laser welding Cleaning Cleaning Drying Thermal spray coating Annealing Inspection Inspection Source: Aus
Slide 6: State-of-the-art continuous roll-to-roll coating line
State-of-the-art continuous roll-to-roll coating line • Continuous roll-to-roll coating for mass production of bipolar plates is an economic and environmentally sound solution. • By using readily available materials, and cutting process steps important cost reductions can be achieved. • Advanced coa
Slide 7: High performance coating
High performance coating Graphite like Carbon • Interfacial Contact Resistance below DOE target of 10 mΩ·cm2 at 140 N/cm2 – ICR equal to gold at contact pressure > 100 N/cm2 • Increase in ICR of < 2 Ω·cm2 after biaxial straining* of 30% and potentiostatic testing in simulated fuel cell environment *
Slide 8: Why enhanced formability?
Why enhanced formability? Stress UTS 103 s-1 Rupture UTS 100 s-1 Material UTS 10-3 s-1 properties and elongation are dependent on the forming speed and Elastic Elastic Elastic region region region this strain rate. Strain
Slide 9: The influence of forming speed
The influence of forming speed Source: Balanethiram, Ohio State University “Enhanced Formability of Sheet Metals at High Workpiece Velocity” Elongation is increasing when the forming Source: “High Strain Rate Source: “High-loading velocity Tensile Deformation Behavior of Al-Mg speed exceeds 1-2 m/s
Slide 10: Main reason for improved formability
Main reason for improved formability • Low speed: Microvoids SEM at coalesce, forming a crack, Low speed perpendicular to loading. 0.01 m/s • High speed: Microvoids joining is retarded due to thermal effects, they grow in an angled direction. SEM at High speed • Greater number of slip bands 10 m/s a
Slide 11: High-velocity formed patterns
High-velocity formed patterns 34 % Examples of formed patterns with Sanergy LT 316L. 38 % Channel forming elongation increasing from 34 to 52%. The 45 % channel pitch varies between 0.9 mm to 1.6 mm. 50 % 52 %
Slide 12: High-velocity formed patterns
High-velocity formed patterns Close-up of high-speed formed pattern of Sanergy LT 316L. Smooth crack- free surface can noticed.
Slide 13: The stamping and forming process
The stamping and forming process Just before forming starts Partly formed Forming just completed V≤20 m/s V≤15 m/s V= 0 m/s A process similar to conventional stamping. The main difference is the forming velocity or speed.
Slide 14: Why a 2-step forming process?
Why a 2-step forming process? More dome-shaped 1-step Necking in area of radii A copy of the protrusion of the tool. 2-step More uniform cross-section, particularly at landings. No necking.
Slide 15: Why a 2-step forming process?
Why a 2-step forming process? 1-step forming A 2-step process enables tough patterns 2-step forming with a channel forming elongation of 50+ % to be formed.
Slide 16: Production line for high-volume production
Production line for high-volume production • Similar forming technology, forming plates from thin sheet metal coil. • Many lines in operation world wide, proven technology • Fully automated high-volume production
Slide 17: Line concept for high volume production
Line concept for high volume production PVD Coating Pre-form High-speed Cutting and and pre-cut forming handling
Slide 18: Accessibility and utilization
Accessibility and utilization Accessibility Incoming material 99% Operator 95% Accessibility material feeding 98% Accessibility forming and cutting presses 95% Accessibility Automation between presses 95% Accessibility high velocity press 95% Accessibility tooling 98% Accessibility unloading and spo
Slide 19: Cost estimation
Cost estimation Assumptions: Production cost Operating 0.02 € o Investment write off: 10 years Labour 0.09 € o 10 million plates per annum Tooling 0.05 € o Plate size 370 mm x 90 mm Depreciation 0.03 € (anode) + 370 x 90 mm (cathode) Material 0.56 € = 0,0666 m2 Yield (95%) 0.03 € o Full production s
Slide 20: Summary
Summary The combination of: o Pre-coated stainless steel o High-speed forming o Effective automated line Enables bipolar plates to be produced at low cost per part and particularly per kW
Slide 21: Thanks for your attention!
Thanks for your attention! Visit Sandvik, AP&T and Cell Impact at our booths, and have the 3D animation tour