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Research Papers

Investigation Into Mechanical Behavior of the Current Collector for the Molten Carbonate Fuel Cell Through Finite Element Analysis Using Hexahedral Mesh Coarsening

[+] Author and Article Information
Chang-Whan Lee

School of Mechanical Engineering
and Aerospace System,
Korea Advanced Institute of
Science and Technology,
Science Town,
Daejeon 305-701, South Korea
e-mail: wonjanglee@kaist.ac.kr

Dong-Yol Yang

School of Mechanical Engineering and
Aerospace System,
Korea Advanced Institute of
Science and Technology,
Science Town,
Daejeon 305-701, South Korea
e-mail: dyyang@kaist.ac.kr

Jong-seung Park

Doosan Heavy Industries and Construction Co.,
Fuel Cell Development Center,
463-1 Jeonmin-dong, Yuseong-gu,
Daejeon 305-811, South Korea
e-mail: jongsueng.park@doosan.com

Yun-sung Kim

Doosan Heavy Industries and Construction Co.,
Fuel Cell Development Center,
463-1 Jeonmin-dong, Yuseong-gu,
Daejeon 305-811, South Korea
e-mail: yunsung.kim@doosan.com

Tae-Won Lee

Doosan Heavy Industries and Construction Co.,
Fuel Cell Development Center,
463-1 Jeonmin-dong, Yuseong-gu,
Daejeon 305-811, South Korea
e-mail: taewon.lee@doosan.com

1Corresponding author.

Contributed by the Advanced Energy Systems Division of ASME for publication in the JOURNAL OF FUEL CELL SCIENCE AND TECHNOLOGY. Manuscript received October 2, 2013; final manuscript received May 22, 2014; published online November 14, 2014. Assoc. Editor: Umberto Desideri.

J. Fuel Cell Sci. Technol 11(6), 061005 (Dec 01, 2014) (10 pages) Paper No: FC-13-1091; doi: 10.1115/1.4028939 History: Received October 02, 2013; Revised May 22, 2014; Online November 14, 2014

The current collector for the molten carbonate fuel cell (MCFC), which is a repeated structure of sheared protrusions, is manufactured from the three-stage forming process. For the precise and efficient simulation of the mechanical behavior of the current collector, the results of the forming process such as the deformed geometry and the distribution of plastic strain should be considered properly. In this work, an efficient method to construct the simulation model of the current collector considering the results of the forming process was introduced. First, hexahedral mesh coarsening was first conducted using the simulation results of the three-stage forming process of a sheared protrusion. Then, the equivalent plastic strain was mapped from the old mesh to the newly generated mesh. Finally, the simulation model for the current collector was constructed by duplicating and reflecting the newly generated mesh. For the verification of the proposed method, various numerical examples were investigated. The simulation results using the proposed method were compared with the experimental results of the three-point bending at 20 °C (room temperature) and 650 °C (operating temperature of the MCFC). From the examples for verification, it was found that the proposed simulation for the current collector was found to be efficient and applicable to the simulation of the mechanical behavior of the current collector for practical application.

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Figures

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Fig. 1

Schematic figure of the MCFC and the metallic bipolar plates

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Fig. 2

Simulation results and experimental results of the three-stage forming process [4]

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Fig. 8

Comparison of the mesh coarsening results (a) simulation result of the three-stage forming process, (b) mesh coarsening results, and (c) comparison of the equivalent plastic strain distribution

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Fig. 7

Results of hexahedral mesh coarsening

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Fig. 6

Conforming mesh of the sheared protrusion

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Fig. 5

Extraction of the desired geometry using STL file format

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Fig. 4

Simulation results of the compression utilizing the simulation results of the forming process [26]

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Fig. 3

Manufacturing metallic bipoloar plate

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Fig. 9

Mesh generation of the large-area current collector for the simulation: (a) mesh coarsening result of the sheared protrusion, (b) mesh generation in the longitudinal direction, (c) mesh generation in the transverse direction, and (d) generated mesh of the current collector

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Fig. 10

True stress–true strain curve

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Fig. 11

Experimental results and load–displacement curve of the unit cell compression

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Fig. 16

Load–displacement curve of three-point bending at 20 °C and 650 °C

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Fig. 12

Comparison of the mechanical behavior of the unit cell between the full model and the proposed model: (a) compression in the longitudinal direction, (b) tension in the longitudinal direction, (c) compression in the transverse direction, and (d) tension in the transverse direction

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Fig. 13

Experimental result of the three-point bending at 20 °C

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Fig. 14

Experimental setup for the three-point bending at 650 °C

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Fig. 15

Finite element model of three-point bending

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Fig. 17

Increase of the yield stress due to the forming effect

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Fig. 18

Maximum plastic strain in the x-direction

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