High-Velocity and High-speed Manufacturing Method
High-Velocity and High-speed Manufacturing Method and Manufacturing Cost Analysis for PEM FC Applications 5th European PEFC and H2 Forum 2015 B0605 About Sandvik Sandvik is a developer and producer of advanced stainless steels, special alloys, titanium and other high-performance materials. About AP&T AP&T is a global supplier and market leader for heat exchanger plates. In general, AP&T provides the sheet metal industries worldwide with complete production systems as well as with stand-alone presses, automation and tooling. About Cell Impact Cell Impact is a global supplier to the manufacturing industry of reliable, integrable and cutting-edge highvelocity units that result in highquality production, greater effectiveness and capabilities that surpass those of conventional machine tooling. The process 316L, t=100/(75) µm Coil Flattening PVD Coating Typical Process Stamping & cutting 7 steps Stamping & cutting 3 steps Laser welding Cleaning Laser welding Cleaning Drying Thermal spray coating Annealing Inspection Source: Austin Power Engineering 2014 Inspection Alternative Process 316L, t=100/(75) µm State-of-the-art continuous roll-to-roll coating line • Continuous roll-to-roll coating for mass production of bipolar plates is an economic and environmentally sound solution. • By using readily available materials, and cutting process steps important cost reductions can be achieved. • Advanced coatings on standard stainless steel exhibit excellent properties for fuel cell bipolar plates. • Versatile, high throughput production coating line PVD Coating Preform & Precutting High-velocity Forming Cutting & Positioning High performance coating Graphite like Carbon • Interfacial Contact Resistance below DOE target of 10 mΩ·cm2 at 140 N/cm2 – ICR equal to gold at contact pressure > 100 N/cm2 • Increase in ICR of < 2 Ω·cm2 after biaxial straining* of 30% and potentiostatic testing in simulated fuel cell environment *Erichsen cupping test High-velocity formed patterns 34 % 38 % 45 % 50 % 52 % Examples of formed patterns with Sanergy LT 316L. Channel forming elongation increasing from 34 to 52%. The channel pitch varies between 0.9 mm to 1.6 mm. Why enhanced formability? Stress UTS 10-3 Tension 316L Ultimate Eq. Stress UTS 100 Rupture UTS 103 Material properties are dependent on speed. Ultimate Tensile Stress is increasing that results in enhanced formability. High Velocity Conventional Strain rate -1 “DynamicalsMechanical Properties of Elastic region J Phys IV France 7 Automotive Thin Plate in Tension, Compression and Shear” Strain The stamping and forming process Just before forming starts Partly formed V≤20 m/s V≤15 m/s Forming just completed V= 0 m/s A process similar to conventional stamping. The main difference is the forming velocity or speed. Why a 2-step forming process? Limited stretching of material from landing 1-step Necking in area of radii A copy of the protrusion of the tool. 2-step More uniform cross-section, particularly at landings. No necking. Why a 2-step forming process? 1-step forming 2-step forming No necking is obvious for tougher patterns. A 2-step process enables tough patterns with a channel forming elongation of 50+ % to be formed. Production line for high-volume production • Similar forming technology, forming plates from thin sheet metal coil. • Many lines in operation world wide, proven technology • Fully automated high-volume production Line concept for high volume production PVD Coating Pre-form and pre-cut High-speed forming Cutting and handling Accessibility and utilization Accessibility Incoming material Operator Accessibility material feeding Accessibility forming and cutting presses Accessibility Automation between presses Accessibility high velocity press Accessibility tooling Accessibility unloading and spot welding Positioning in process Total accessibility for planned production Utilization Real production speed (no /hours) Hours planned for production Possible production / Year Theoretical max no of strokes / Year Estimated utilization 99% 95% 98% 95% 95% 95% 98% 95% 98% 72.1% 1,298 8,038 10,431,192 14,688,000 71.0% Cost estimation Assumptions: o Investment write off: 10 years o 10 million plates per annum o Plate size 370 mm x 90 mm (anode) + 370 x 90 mm (cathode) = 0,0666 m2 o Full production speed. Material 316L. o Production location (&cost): Sweden Production cost Operating Labour Tooling Depreciation Material Yield (95%) Maintenance: Total per plate: 0.02 0.09 0.05 0.03 0.56 0.03 0.02 0.81 € € € € € € € € Total cost per coated bipolar plate assembly, incl. laser welding is approx. 0.97 €. Thanks for your attention! Visit Sandvik, AP&T and Cell Impact at our booth for 3D animation and more info
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