Abstract
A low CTE bipolar plate is fabricated from a NiAl intermetallic and a ceramic filler material. By using inert, ceramic filler materials the intermetallic reaction of the NiAl system is controlled resulting in netshape formed plates with CTE comparable to the electrolyte and electrode ceramic layers. In addition, the combustion synthesis reaction moderated by the ceramic filler material creates significant porosity in the NiAl microstructure yielding a highly thermal shock resistant substrate material for the subsequent plasma deposited electrode and electrolyte layers. This paper outlines the powder metallurgy process parameters necessary to form these low CTE intermetallic plates.
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