Experimental investigation of forming metallic bipolar plates by hot metal gas forming (HMGF)

Abstract

In this study, the effects of various parameters in forming of aluminum alloy bipolar plates using hot metal gas forming (HMGF) were studied. The effect of applied gas pressure P, channel width w, and outer fillet radius of die R were investigated. For evaluation of the forming state, both thickness distribution and filling profile of formed plates were measured. The results showed that increase in the gas pressure led to decrease in the blank thickness and increase in the filling profile. Moreover, by increasing the outer fillet radius, the maximum thickness reduction at formed plates was decreased and filling percentage was increased. Different aspect ratios h/w of rigid die were applied. It was concluded that by increasing aspect ratio, the thickness reduction was increased and the filling percentage was decreased. Finally, high accurate plates were fabricated in experimental tests which confirmed the feasibility of forming the thin bipolar plate by HMGF.