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In this investigation, the through mask electrochemical machining (TMEMM) is used to generate microchannel structures on metal bipolar plates. By taking serpentine flow channels fabrication as an example, the experiment system of the electrochemical machining is designed and built to evaluate the effect of machining parameters such as machining time and current density on the morphology of the flow channel. The experimental results show that the TMEMM can be utilized to process micro-channels on metal surfaces effectively and the island morphologies inside of the flow channels can be removed with increased machining time. Moreover, the machining efficiency and localization can be further improved by selecting a pulse voltage between 20V and 30V.

Experimental Study of Metal Bipolar Plate Microchannels Fabrication Using the Through Mask Electrochemical Machining