Energy Equipment and Systems

Energy Equipment and Systems

Finite element analysis of electrical conduction in additively manufactured SS316L bipolar plates for PEM fuel cells

Document Type : Research Paper

Authors
Rajat Choudhary 1
Eswara Krishna Mussada 2
Anoop Kumar Shukla 3
1 Hyundai Motor India, Delhi, India
2 Amity Institute of Technology, Amity University Uttar Pradesh, Noida, India
3 Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India
10.22059/ees.2025.2056120.1510
Abstract
This study presents a numerical simulation-based analysis of the electrical conductivity of SS316L bipolar plates against the most widely used graphite plates for Proton Exchange Membrane Fuel Cells (PEMFCs). A well-defined three-dimensional model of a bipolar plate with a serpentine channel has been made with some customization to improve the flow, as serpentine is often utilized in fuel cell stacks. The serpentine flow channel design was chosen for its capacity to encourage equal current distribution and reduce localized resistance, consequently solving fundamental limitations that have long held back the commercial viability of PEMFC bipolar plates as they are known to be one of best for flow distribution with few issues of pressure drop which can be solved with modifications in the design. The simulation evaluated voltage potential and surface current density across bipolar plates of SS316L and graphite. SS316L exhibited a significantly lower effective resistance (2.29×10⁻⁷ Ω) compared to graphite (3.32×10⁻⁵ Ω), under identical conditions. The comparison indicates that SS316L possesses much lower effective resistance compared to graphite, making it a cost-effective and long-lasting alternative for the production of bipolar plate. This paper comprehensively explores the relationship between conduction performance, geometric design, and material properties, thereby contributing towards the optimal design of bipolar plates aimed at enhancing fuel cell efficiency.
Keywords
Fuel Cell
Energy Storage
Additive Manufacturing
Automobiles
Electric Vehicles

Subjects

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Energy Equipment and Systems
Volume 13, Issue 4 - Serial Number 4
Autumn 2025
Pages 431-443