Challenges for the commercialization of metallic bipolar plates for PEM fuel cells

Transcription

1 f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel f-cell Stuttgart; 2 nd of October 2013 Challenges for the commercialization of metallic bipolar plates for PEM fuel cells Dana Holding Corporation Power Technology Group Reinz-Dichtungs-GmbH Honesty & Integrity Good Corporate Citizen Open Communication Continuous Improvement

2 Content DANA and its Fuel Cell Products Key challenges Technology demonstration Conclusion f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 2

3 Dana Overview Founded in 1904 Based in Maumee, Ohio 2012 sales: $7.2 billion Global customers and operations Production facilities in 27 countries 15 technical centers 92 major facilities Customers in 125 countries Nearly 25,000 employees Dana Corporation, Maumee, Ohio, USA REINZ-Dichtungs-GmbH, Germany f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 3

4 Dana Product Portfolio Engine oil cooling Transmission oil cooling Fuel cooling Charge air cooling Small engine cooling Driveshafts Axles / differentials Cylinder-head gaskets Secondary gaskets Cylinder-head cover modules Thermal Acoustical Protective Shielding Valve stem seals f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 4

5 Dana Advanced Technologies f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 5

6 ICE Plate Inter Cell Element In Production Coolant is used to cool Lithium Ion battery cells heat exchangers made of a brazed aluminum plate pair Flow path designed to provide uniform coolant temperature across plate High Cleanliness requirements High volume production f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 6

7 Dana Fuel Cell Product Portfolio Fuel Storage & Delivery Balance of Plant Fuel Cell Stack Fuel Processor Power Output f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 7

8 Metallic Bipolarplatte at Dana in Neu-Ulm f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 8

9 High volume production readiness since 2004 f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

10 Key challenges for commercialization: no commitment from the market uncertain volume projections steep ramp up curve volatile market demands demanding component cost expectations f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 10

11 Key challenges for commercialization: uncertain volume projections no commitment from the market steep ramp up curve volatile market demands demanding component cost expectations f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 11

12 Cost challenge: high level of integration and standardization material selection design to cost unit cell approach f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 12

13 Cost challenge: high level of integration and standardization material selection design to cost unit cell approach f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 13

14 Dana s standard customized Metallic Bipolar Plate Module stamping process for micro structured products at high speed contact resistance in mwcm ,3 In-house low cost (material and process) coating process on low contact resistance of Frieda 1N/mm 2 cost substrates 39, ,1 raw material graphite composite gold coated 22,0 low cost coated 20 12,1 10,6 10,4 10 6,8 0 RNZ FCS RNZ FCS Composite 2 RNZ FCS RNZ FCS RNZ-FCS RNZ FCS RNZ FCS joining process for micro structures Proprietary fully integrated sealing solution f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 14

15 DANA process flowchart to the standardized metallic bipolar plate module Incoming Inspection Stamping and Cutting with Progressive Die Joining Random Quality inspection Random Quality inspection Random Quality inspection DANA Coating Process Sealing process RNZ final inspection Packaging and Shipment Customer f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

16 Cost challenge: high level of integration and standardization material selection design to cost unit cell approach f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 16

17 Test inventory for metallic bipolar plates since 2001: Basic electrochemical analysis: 246 different base materials 44 different coating options Immersion and aging tests: 129 materials Conductivity analysis: 162 different base materials 31 different coating options Fuel Cell stack test: More than test hours over the last 13 years 181 various stack configurations Gegenelektrode Metallstab Glasrohr Stickstoff-Spülung Referenzelektrode Elektrode Kunststoffgehäuse f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 17

18 Test conditions for the material test stack Frieda DANA FC test stands: Test conditions: cooling outlet temperature 80 C Ambient pressure, humidified with bubblers, hydrogen humidified at 78 C, air humidified at 60 C, hydrogen stoichiometry 2 air stoichiometry 5 DANA Frieda Lab Stack: active area 100 cm² compression force 10 kn up to 6 cells f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 18

19 Material durability testing of Dana s partialc coating f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 19

20 Material durability testing of Dana s partialc coating lifetime prediction (10%): > 8000 h extrapolated f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 20

21 Dana's conductive coating development Through Plate Resistance (TPR) of Different Coatings on the Bipolar Plate Frieda Lab specimen metallic bipolar plate Frieda I Gold plated copper plates Sample GDL U contact point for voltage measurement, galvanically isolated metallic bipolar plate: 0.1 mm, laser welded, identical anode and cathode flowfield, 100 cm² active area channel depth 0.5 mm, additional metallic, silicon screen print seal frames Constant DC current 100 ma/cm 2 between the two gold plates. Uniformly distributed contact points, isolated from the current connectors Voltage drop at different compression forces (e.g. 0.2 / 0.5 / 1.0 / 1.5 / 2.0 N/mm 2 ) f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 21

22 In-House Conductive Coating Development at Dana Through-Plate Resistance TPR of the Frieda Bipolar Plate Including 2 GDLs. Current is 1A/cm² contact resistance in mohm cm ,1 contact resistance of DANA Metallic Bipolar 1N/mm 2 raw metal graphite composite gold coated DANA low cost coating ,3 39,0 38, ,0 17,6 12,1 10,6 9,8 7,9 7,8 6, L RNZ RNZ Composite molded RNZ Composite machined RNZ RNZ RNZ RNZ RNZ RNZ f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

23 complete cell with partialc SS316L plain PVD Gen2a 1100 h PVD Gen2b 1100 h Au xx nm 1300 h partialc SS316L 3000 h partialc SS h ohmic resist. in mohm*cm² Dana's low cost conductive coating development Unit cell resistance f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 23

24 ohmic resist. in mohm*cm² Dana's low cost conductive coating development Plate+GDL resistance BOL and EOL PVD Gen2a 1100 h PVD Gen2b 1100 h Au xx nm 1300 h partialc SS316L 3000 h partialc SS h f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 24

25 degredatin in µv/h Dana's low cost conductive coating development Unit cell degradation (CCM, GDL plus bipolar plate) PVD Gen2a 1100 h PVD Gen2b 1100 h Au xx nm 1300 h partialc SS316L 3000 h partialc SS h f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 25

26 Cost challenge: high level of integration and standardization material selection design to cost unit cell approach f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 26

27 Dana s Integrated Metallic Bead Seal f-cell award in gold 2004 Benefits: Sealing is integrated part of the metallic bipolar plate module Simultaneous production process of the seal together with the bipolar plate Minor gas permeation, due metal Durable elasticity, minor creep Design flexibility individual adjustment to plate, port geometry and soft goods Simplification of the port flow-field connection Simplification of the assembly process f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 27

28 Sealing approach MEA with a injection molded gasket GDL PTFE Kat. GDE Membrane/ CCM GDE/GDL flush-cut 5 - Layer MEA vehicles per year Silicone/ rubber ca. 120 C sec MEAs p.a (45 sec.) = 21 Injection molding cells f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 28

29 21 machines to mold seals to the MEA f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 29

30 Laminated MEA with film frame for Dana s MBPP module GDL PTFE Kat. GDE GDE Frame material Membrane/ CCM GDE/GDL Frame material cut out active area Contour cut MEAs p.a = 12 m/min on one machine f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 30

31 Cost challenge: high level of integration and standardization material selection design to cost unit cell approach f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 31

32 Development path for Metallic Bipolar Plates at DANA IDEA Initial Spec. Concept Phase DFM DTC Prototypes Production Customer A Joint development effort Joint design for manufacturing, prototype production and testing Final Component Specificatio n and Production Customer B Customer C f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 32

33 Design tools at Dana for MBPP CFD simulation and verifikation of coolant flow CFD analysis of port design CFD analysis of optimizes coolant flow FEA analysis of seal design f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 33

34 Studies on soft goods frame material judge of frame material to find the best adjustment of components f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

35 Thickness in mm Studies on soft good Different MEAs - in Test Tool 0,52 MEA 1 0,51 0,50 MEA 2 0,49 0,48 MEA 3 0,47 0,46 0,503; 0,454 0,45 0,44 0,704; 0,439 0,43 0,499; 0,444 0,700; 0,428 1,000; 0,418 0,42 0,41 0,40 0,39 0,501; 0,381 0,38 0,712; 0,370 0,37 0,999; 0,357 0,36 0,35 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 Pressure in N/mm² f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

36 Kraft in N/mm Seal studies: Force Deflection Curves Seal 10,00 Kraft-Weg-Kurven Sickenprüflinge 9,00 8,00 7,00 6,00 5,00 4,00 3,00 2,00 1_0,1_m_B_m_Siebdr 2_0,1_m_B_m_Siebdruck 3_0,1_m_B_m_Siebdruck 4_0,1_m_B_m_Siebdruck 5_0,1_m_B_m_Siebdruck 6_0,1_m_B_m_Siebdruck 1,00 0,00 0 0,05 0,1 0,15 0,2 0,25 0,3 Weg in mm f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

37 Resistance in mohm*cm² Contact resistance GDL flow field Resistance measurement Wiederstandsmessung at different mit Testwerkzeug contact pressures "Louise" Material: with Graphitebeschichtung FC-C 42P* GDL: SGL 25BCH 55 GDL: Gore CNW 30B ,00 0,50 1,00 1,50 2,00 Pressure in N/mm 2 f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

38 Seal behavior test sample of a representative cell model Bipolar plate, MEA subgasket, 2 GDL f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

39 Local contact pressure simulation f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel FEA analysis of seal design

40 CFC simulation to optimize plate performance CFD analysis of optimizes coolant flow f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel

41 Technology demonstration f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 41

42 Proof of concept by technology demonstration f-cell Award in Gold Stuttgart September 2010 Development of a design for manufacturing workflow Development of bipolar plate and stack assembly features Demonstrate robustness and durability f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 42 42

43 Component simplification by integration Metallic bipolar plate module with integrated seal and low cost coating Integrated laminated MEA f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 43

44 Assembly simplification Ideal pick an place structures f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 44

45 Bead seal demonstrator Eva XXL f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 45

46 Leak rates of the bead seal demonstrator Eva XXL f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 46

47 Conclusion Dana has established design for manufacturing tools and processes to turn around customer requirements in a approved and reliable workflow Dana has established a supply chain, design solutions and materials to enable the commercialization of metallic bipolar plates. Dana has established production capabilities and equipment to meet the growing volumes and increasing product demands of the fuel cell industry. Dana is able to supply a one shop solution for a metallic bipolar plate module. Dana provides a solution not just a component f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 47

48 DANA Neu-Ulm PEFC Development recognition: continuity > sustainability > dedication > passion > success 2002 General Motors supplier of the year 2004 Bavarian Energy Award 2004 f-cell award in Gold 2009 PSA technology achievement award 2010 f-cell award in Gold f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 48

49 f-cell Stuttgart 2 nd October 2013; Dr. Raimund Stroebel 49 approx BPP