{"title":"Local Reinforcement of a Fuel Cell End Plate for Package Improvements Using Steel–Aluminium Hybrid-Casting Technology","authors":"Florian Mielke, Sharath Christy Anand, Xiangfan Fang","doi":"10.1007/s12239-024-00129-0","DOIUrl":null,"url":null,"abstract":"<p>In this research work, a method for integrating a local reinforcement structure in a medium-pressure plate (MPP) for fuel cell electric vehicle (FCEV) applications was developed using steel–aluminium hybrid-casting technology. Using this technology, it is possible to create a bonded enclosure of a steel reinforcement patch with the cast aluminium pressure plate to increase its stiffness and achieve 15% package space savings. A load-compliant, manufacturable patch was chosen and optimised for maximum stiffness gains using non-linear static finite-element (FE) calculations. Special form and process requirements due to hybrid-casting technology were examined and secured with casting simulations. The reinforcement patch was manufactured and coated with a unique aluminium–silicon coating enabling a ductile material connection between the steel and aluminium, and casting trials were conducted to create prototypes. Additionally, the insulating plastic layer on top of the metallic pressure plate carrier was substituted from costly short-fibre-reinforced high-performance plastic to cheaper and stiffer glass-mat reinforced thermoplastic material. Finally, the new hybrid MPP was tested mechanically, and the FE-Model was verified. In summary, through the package gain, 2.1 kW more power output and 11% less weight could be achieved while remaining stiffness neutral.</p>","PeriodicalId":50338,"journal":{"name":"International Journal of Automotive Technology","volume":"40 1","pages":""},"PeriodicalIF":1.5000,"publicationDate":"2024-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"International Journal of Automotive Technology","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1007/s12239-024-00129-0","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}
引用次数: 0
Abstract
In this research work, a method for integrating a local reinforcement structure in a medium-pressure plate (MPP) for fuel cell electric vehicle (FCEV) applications was developed using steel–aluminium hybrid-casting technology. Using this technology, it is possible to create a bonded enclosure of a steel reinforcement patch with the cast aluminium pressure plate to increase its stiffness and achieve 15% package space savings. A load-compliant, manufacturable patch was chosen and optimised for maximum stiffness gains using non-linear static finite-element (FE) calculations. Special form and process requirements due to hybrid-casting technology were examined and secured with casting simulations. The reinforcement patch was manufactured and coated with a unique aluminium–silicon coating enabling a ductile material connection between the steel and aluminium, and casting trials were conducted to create prototypes. Additionally, the insulating plastic layer on top of the metallic pressure plate carrier was substituted from costly short-fibre-reinforced high-performance plastic to cheaper and stiffer glass-mat reinforced thermoplastic material. Finally, the new hybrid MPP was tested mechanically, and the FE-Model was verified. In summary, through the package gain, 2.1 kW more power output and 11% less weight could be achieved while remaining stiffness neutral.
期刊介绍:
The International Journal of Automotive Technology has as its objective the publication and dissemination of original research in all fields of AUTOMOTIVE TECHNOLOGY, SCIENCE and ENGINEERING. It fosters thus the exchange of ideas among researchers in different parts of the world and also among researchers who emphasize different aspects of the foundations and applications of the field.
Standing as it does at the cross-roads of Physics, Chemistry, Mechanics, Engineering Design and Materials Sciences, AUTOMOTIVE TECHNOLOGY is experiencing considerable growth as a result of recent technological advances. The Journal, by providing an international medium of communication, is encouraging this growth and is encompassing all aspects of the field from thermal engineering, flow analysis, structural analysis, modal analysis, control, vehicular electronics, mechatronis, electro-mechanical engineering, optimum design methods, ITS, and recycling. Interest extends from the basic science to technology applications with analytical, experimental and numerical studies.
The emphasis is placed on contributions that appear to be of permanent interest to research workers and engineers in the field. If furthering knowledge in the area of principal concern of the Journal, papers of primary interest to the innovative disciplines of AUTOMOTIVE TECHNOLOGY, SCIENCE and ENGINEERING may be published. Papers that are merely illustrations of established principles and procedures, even though possibly containing new numerical or experimental data, will generally not be published.
When outstanding advances are made in existing areas or when new areas have been developed to a definitive stage, special review articles will be considered by the editors.
No length limitations for contributions are set, but only concisely written papers are published. Brief articles are considered on the basis of technical merit.