Fuel cells, particularly proton exchange membrane fuel cells (PEMFCs), are a crucial factor in achieving the Paris Agreement on climate change and other environmental and climate goals, as they do not emit or produce toxic emissions. They significantly contribute to reducing greenhouse gas emissions. Consequently, PEMFCs are increasingly considered a widely adopted solution as both an energy source and storage system, making them a key component of the future hydrogen-based economy. They enable sustainable mobility while gaining importance in various energy applications with the increasing share of renewable energy sources.

One of the key approaches to adapting PEMFC design for specific applications depends on the development of bipolar plates (BPPs) and the manufacturing technologies that limit the final performance of fuel cells. Bipolar plates play a crucial role in fuel cell assembly. To ensure an acceptable level of fuel cell output power and a long cell lifespan, BPPs must exhibit excellent electrical and thermal conductivity, as well as mechanical and chemical stability in an acidic (pH 2–3) and oxygen-rich environment. Due to the need for chemical and electrochemical stability, the main structural challenges include the microstructure, surface and subsurface integrity of metallic BPPs, and the manufacturing processes that ensure proper geometry and distribution of the flow field channels for hydrogen and air. Overcoming these three primary challenges is essential to achieving optimal PEMFC performance.

The industry faces a significant challenge in developing and manufacturing titanium alloy BPPs for PEMFC applications, where the desired geometry and surface integrity of the processed BPPs have not yet been fully achieved while maintaining other key properties. Additionally, an optimal BPP design in correlation with suitable manufacturing processes has not yet been established. This highlights a strong need for research into defining production processes and their parameters in relation to fuel cell working models and resource efficiency to enhance fuel cell performance.

The main goal of the proposed postdoctoral project is to conduct significant research and development of an innovative manufacturing process and surface modification techniques for producing titanium alloy BPPs to enhance the performance and lifespan of PEMFCs.

The project represents a breakthrough that effectively contributes to the advancement of fuel cells and bipolar plates, with a focus on innovative manufacturing technologies and surface modification techniques. It will address key research areas and provide innovative contributions to the development of sustainable automotive and industrial applications by utilizing state-of-the-art manufacturing processes.

The project is structured so that the defined objectives also represent individual work packages (WP) of the project:

• Objective 1: Detailed review and research of already recognized flow channel designs for bipolar plates (WP1)
• Objective 2: Optimization of the geometric properties of bipolar plates (WP2)
• Objective 3: Research and development of an innovative cryogenic manufacturing process for bipolar plates (WP3)
• Objective 4: Research on further surface modification of bipolar plates (WP4)
• Objective 5: Cell assembly and experimental validation (WP5)

Project duration: 01.10.2022 – 30.09.2024

Project status: completed