Investigation of the assembly for high-power proton exchange membrane fuel cell stacks through an efficient equivalent model.

• Methodology using composited equivalent is built to evaluate stack mechanical state. • The cells approaching to mid-stack have more uniform pressure. • Numerical results show good agreements with experimental results. • Nonlinear compression behavior of MEA is applied in high-power PEM fuel cell stack. • Equivalent model has higher computational efficiency than traditional finite element model. A high-power proton exchange membrane fuel cell (PEMFC) stack usually composes many cells, which induce high difficulty in evaluating its mechanical state of stack assembly. A methodology based on composite model and material property equivalent is developed to predict the mechanical state in PEMFC stack. In this methodology, the stack system is modeled based on a finite element model (FEM), in which bipolar plate (BPP) and membrane exchange assembly (MEA) are combined into a composite component. Experiments with stamped BPP are carried out to validate the FEM of the stack, and both the predicted clamping force and endplates deformation of FEM have a great agreement with the experimental results. Based on the methodology, it is found that more uniform pressure distribution can be generated when high-stiffness endplates are applied and cell number of the stack increases. The cells approaching to mid-stack have more uniform pressure. The pressure distribution of the stack is very sensitive to the compression ratio. High compression ratios leads to large endplate deformation, which increases the average pressure deviation between simulated value and design value, and also increases non-uniformity of pressure distribution. This methodology offers the possibility of evaluating the mechanical state of high-power fuel cell stack and greatly improves the computational efficiency. [ABSTRACT FROM AUTHOR]