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In molten carbonate fuel cell (MCFC) systems, it is known that the shape of corrugated plates has a significant influence on performance, durability, and cost. A corrugated plate with a repeating open trapezoidal-shaped slot supports membrane electrode assembly and provides a gas flow channel. To increase the efficiency of the MCFC, the slot between the corrugated and center plates has a relatively large contact length. However, increasing the contact length of the slot increases the risk of necking or fracture generation at the corner of the slot. Therefore, we focus on the development of forming technology of corrugated plate which has large contact length of slots without any necking or fracture. To this end, numerical simulation was conducted to determine the appropriate process and tool design. In the simulation, to capture shear fracture during the forming process of slots, the normalized Cockroft–Latham ductile fracture model was used. The critical value for slitting and fracture was evaluated by comparing the deformed shapes in the slitting plane obtained from experimental and simulation results. Based on simulation results, a reasonable design concept of the two-stage forming process was suggested to increase the contact length of the slot without necking or fracture. In addition, the experiment results confirmed the validity of the proposed forming process and tool design.

Design of a Forming Process for Increasing the Contact Length of Corrugated Plates in Molten Carbonate Fuel Cells