Optimization of Process Parameters in Resistance Seam Welding of Polymer Electrolyte Membrane Fuel Cell Bipolar Plates Using a Combined Experimental and Numerical Approach
نویسندگان
1 Department of Mechanical Engineering, Babol Noushirvani University of Technology, Babol, Mazandaran, Iran
2 Department of Mechanical Engineering, Babol Noushirvani University of Technology, Babol, Mazandaran, Iran
3 Department of Mechanical Engineering, Babol Noushirvani University of Technology, Babol, Mazandaran, Iran
4 Department of Mechanical Engineering, Islamic Azad University, Qaemshahr Branch, Qaemshahr, Iran
doi
10.5829/ije.2026.39.12c.11چکیده
Bipolar plates are among the key components of polymer electrolyte membrane fuel cells (PEMFCs), responsible for electrical conductivity, reactant distribution, heat removal, and internal sealing. Given their contribution of nearly 80% of the stack weight and 45% of its cost, improving the fabrication process of these plates is crucial for the large-scale commercialization of PEMFCs. Achieving a reliable mechanical and electrical joint between bipolar plates is one of the fundamental challenges in manufacturing. In this study, resistance seam welding (RSW) was investigated for joining 0.1 mm-thick AISI 304 stainless steel bipolar plates. A three-dimensional electro-thermal model was developed in COMSOL Multiphysics, and the influence of three key process parameters electrode traverse speed (100, 200, 300 mm/min), discharge energy (5.5, 8, 14 Ws), and electrode force (20, 40, 60 N) on the temperature distribution and weld nugget formation was analyzed. Simulation results were validated and complemented through experimental lap shear and peel tests. Statistical analysis of the experimental results revealed that discharge energy had the most significant effect on weld quality, whereas electrode speed and force had relatively smaller impacts. The optimal condition was achieved at 100 mm/min traverse speed, 8 Ws discharge energy, and 20 N electrode force, producing lap shear and peel strengths of 537 N and 487 N, respectively, with uniform thermal distribution and proper nugget overlap. These results demonstrate that precise control of process parameters can provide a cost-effective and practical alternative to laser welding for metallic bipolar plate fabrication.
