Dana Holding Corporation€¦ · contact resistance of Frieda BPP @ 1N/mm 2 22,0 12,1 10,6 10,4 6,8 28,1 39,0 43,3 0 10 20 30 40 50 60 RNZ FCS 05-13 RNZ FCS 05-04 Composite 2 RNZ

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Dana Holding Corporation

DANA metallic bipolar plates – enabler for

the European AutoStackCore stack platformDr. Joachim Scherer, Manager R&D Fuel Cell

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

Project framework AutoStackCore

►Project schedule

2

1 6 12 18 24 30 36 40

Specification

Design evolution 1

Design evolution 2

Design evolution 3

Cost engineering

today05/2013

►Project goal: Development of an automotive 95kW stack

►Superior power density, performance and durability

►Meeting commercial target cost

►Partner

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

DANA metallic bipolar plate technologies -

enabler for the AutoStackCore stack platform

3

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

DANA customizable Metallic Bipolar Plate module standard

4

contact resistance of Frieda BPP @ 1N/mm2

22,0

12,110,6 10,4

6,8

28,1

39,0

43,3

0

10

20

30

40

50

60

RNZ FCS

05-13

RNZ FCS

05-04

Composite

2

RNZ FCS

05-12

RNZ FCS

05-17

RNZ-FCS

05-23

RNZ FCS

05-10

RNZ FCS

05-14

conta

ct

resis

tance in m

Wcm

2

gold coated

low cost coated

graphite composite

raw material

Proprietary, fully integrated

bead seal with superior

sealing performance

In-house low cost coating

(material and process) on

low cost substratesJoining process for

micro channels and

thin base materials

High speed stamping process for

micro structured plates (≤ 100µm)

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp. 5

DANA metallic bipolar plate technologies -

enabler for the AutoStackCore stack platform

►Conductive coating technology

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

DANA partialC coating in-situ durability test

6

Extrapolated lifetime prediction

(BoL -10%): > 7000 h

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

contact resistance of DANA Metallic Bipolar Plate @ 1N/mm2

7,99,810,612,117,622,0

38,039,043,3

157,1

6,87,8

0

20

40

60

80

100

120

140

160

316L

RNZ 0

5-13

RNZ 0

5-04

Com

posite

mold

ed

RNZ 0

5-12

Com

posite

mach

ined

RNZ 0

5-17

RNZ 0

5-23

RNZ 0

5-10

RNZ 0

5-28

RNZ 0

5-30

RNZ 0

5-14

conta

ct re

sis

tance in m

Ohm

cm

2

gold coated

DANA low cost coating

graphite composite

raw metal

DANA Conductive Coating Development

► Through-Plate Resistance TPR of BPPs and coatings

► “Frieda” Metallic Bipolar Plate between 2 GDLs

► Current density 1A/cm², 100 cm²

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

DANA coating vs. global benchmark

►TPR values BoL and after 880h of dynamic stack test

8

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

Coating benchmark - through plate resistance

9

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp. 10

DANA metallic bipolar plate technologies -

enabler for the AutoStackCore stack platform

►Metallic bead seal technology

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

Layout and optimization of the bead seal

Standard workflow:

► Analysis of the compression behavior of MEA and sub-gasket

► Designing the bead seal to match height and compression behavior of the softgoods

► FE analysis to optimize the compression of the bead seal11

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

Seal behavior

►Layout of a typical bipolar plate bead seal vs. MEA properties

Tolerance range of MEA ± 30µm

Co

mp

ressio

n f

orc

e seal working range

design point

Seal height in mm

- Force-deflection curve of MEA

- Force-deflection curve of seal

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp. 13

Leak rates of the bead seal demonstrator

„Eva XXL“ 370 cell stack

normalized leakage in (mbar*l)/(s*mm)

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp.

AutoStackCore Evolution 1 Stacks

►Evolution 1 status

►20-cell short stacks for extensive performance and durability testing► Easy and robust stack setup, reliable leak tightness, high performance

► Stable even at low stoichiometry, freeze start from -20°C

►330-cell full size stack for design and performance validation► Perfect performance scale-up, very good dynamic operation behavior

14

AutoStack Core Performance of Evolution 1 full size stack

Power 94 kW max cont.

99 kW peak

Stack power densityIncl. Endplates

2.6 kW/l max cont.

2.8 kW/l peak

Operating Point 631 mV @ 1.5A/cm2

Operating temp. 75°C

Operating pressure 200 kPa

13.04.2015 Hannover Fair 2015 – Dr. Joachim Scherer © DANA Holding Corp. 15132.4

00 A

sC

BP

P

Thank you for your kind attention!

Visit the original stack

@ our booth B71

The funding of the project AutoStack-CORE (GA 325335) within the Fuel Cells & Hydrogen Joint Undertaking (FCHJU) is gratefully acknowledged