Aluminum sheet material for separator of fuel cell and manufacturing method therefor

Abstract

According to an embodiment, the aluminum sheet material for a separator of a fuel cell is used for forming a separator applied to a fuel cell stack and comprises 9-10 wt % of Mg; and the balance of Al and inevitable impurities, wherein the aluminum sheet material has cube texture and an R-cube texture formed therein. An aluminum sheet material for a separator in a fuel cell retains a thickness of 0.5 mm or less and exhibits excellent yield strength and elongation, and a manufacturing method therefor.

Claims

1. A method for manufacturing an aluminum sheet material for a separator of a fuel cell, the method comprising steps of: casting a molten metal, which contains 9-10 wt % of Magnesium (Mg), based on a total wt % of the molten material, a balance of Aluminum (Al) and inevitable impurities, to prepare a cast material having a rod shape; cold rolling the cast material into a rolled plate; stacking multiple copies of the rolled plate to form a stacked rolled plate product; cold-pack rolling the stacked rolled plate product to prepare a sheet material; and thermally treating the sheet material.

2. The method of claim 1, wherein, in the casting step, the molten metal further comprises at least one of 0.12 wt % or less of Manganese (Mn) or 0.12 wt % or less of Chromium (Cr), based on the total wt % of the molten material.

3. The method of claim 1, wherein, in the cold-pack rolling step, the stacked rolled plate product is rolled at a temperature of less than 100° C.

4. The method of claim 3, wherein, in the cold-pack rolling step, the stacked rolled plate product is rolled at room temperature.

5. The method of claim 3, wherein, in the cold-pack rolling step, the stacked rolled plate product is rolled to a thickness of 0.5 mm or less.

6. The method of claim 1, wherein, in the thermal treating step, the sheet material is thermally treated at 350-400° C. for 30-60 minutes.

7. A method for manufacturing an aluminum sheet material for a separator of a fuel cell, the method comprising steps of: casting a molten metal, which contains 9-10 wt % of Magnesium (Mg), based on a total wt % of the molten material, a balance of Aluminum (Al) and inevitable impurities, to prepare a cast material having a rod shape; extruding the cast material to prepare an extruded material having a plate shape; cold rolling the extruded material into a rolled plate; stacking multiple copies of the rolled plate to form a stacked rolled plate product; cold-pack rolling the stacked rolled plate product to prepare a sheet material; and thermally treating the sheet material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other aspects, features and advantages of the present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 shows changes in texture state according to manufacturing steps and thermal treatment conditions;

(3) FIG. 2 shows orientation distribution function analysis results according to thermal treatment conditions;

(4) FIG. 3A is an electron microscopic image of the specimen of Comparative Example 1 in Table 1; and

(5) FIG. 3B is an electron microscopic image of the specimen of Example 1 in Table 1.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(6) Exemplary embodiments of the present disclosure will be described below in more detail with reference to the accompanying drawings. The present disclosure may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

(7) The aluminum sheet material for a separator of a fuel cell according to the present disclosure, which is used for forming a separator that is applied to a fuel cell stack, has a cube texture and a rotated cube (R-cube) texture formed therein by optimizing contents of main alloy components and thermal conditions, thereby exhibiting improved yield strength and elongation.

(8) In detail, the aluminum sheet material comprises 9-10 wt % of Mg and a balance of Al and inevitable impurities. In an embodiment, the aluminum sheet material may further comprise either or both of: 0.12 wt % or less of Mn; and 0.12 wt % or less of Cr.

(9) In the present disclosure, the reason why the alloy components and the amounts thereof are limited is as follows. Unless otherwise stated, “%”, when representing the unit of amount of component, refers to “wt %”.

(10) Magnesium (Mg): 9-10%

(11) Magnesium (Mg), which is a solid solution hardening element, interferes with dislocation and reduces stacking fault energy. Hence, the element obstructs dislocation cross slip and increases the work hardening exponent. As a result, the strength and the elongation are both increased with the decrease of local deformation. Too small a content of magnesium (Mg) brings about only a slight improvement in strength and elongation. Thus, magnesium is contained in an amount of 9% or higher.

(12) When magnesium (Mg) is contained at a content of 9% or higher, the precipitation phase of Al.sub.3Mg.sub.2 appears. Through control of the generation of such precipitation phase, an improvement in strength and formability can be guaranteed. However, a magnesium (Mg) content exceeding 10% causes the problem of decreasing the elongation. Therefore, the content of magnesium (Mg) is limited to the range of 9-10%.

(13) Manganese (Mn): 0.12% or Less

(14) Manganese (Mn), which is an element enhancing processability at high temperatures, provokes the precipitation of fine dispersion phases and suppresses the growth of recrystallized grains upon homogenization to enhance processability. However, when the content of manganese (Mg) exceeds 0.12%, the dispersibility of the precipitation phases is lowered and micro cracks are generated around the crowded precipitation phases upon rolling. Thus, the content of manganese (Mn) is limited to up to 0.12%.

(15) Chromium (Cr): 0.12% or Less

(16) Chromium (Cr), which increases strength and deep drawing, forms a fine intermetallic compound to make grains fine. However, a content of chromium (Cr) exceeding 0.12% decreases the elongation with the increasing of yield strength. Thus, the content of chromium is limited to up to 0.12%.

(17) Except the aforementioned ingredients, the rest is accounted for by aluminum and inevitable impurities.

(18) Below, a description will be given of a method for manufacturing an aluminum sheet material having the composition for a separator of a fuel cell.

(19) According to an embodiment thereof, the present disclosure provides a method for manufacturing an aluminum sheet material for a separator of a fuel cell, the method comprising the steps of: preparing a molten metal having the aforementioned composition; casting a molten metal to prepare a rod-shaped as-cast material; extruding the as-cast material into a plate-like extruded material; cold rolling the extrusion material into a rolled plate; cold-pack rolling the rolled plate to prepare a sheet material, with multiple copies of the rolled plate being stacked; and thermally treating the sheet material.

(20) In an embodiment, the casting step, the extruding step, and the cold rolling step are carried out according to a typical manufacturing method for sheet materials. In this regard, the step of extruding the as-cast material may be omitted, but may be conducted in order to minimize pores and internal defects in the as-cast material.

(21) However, after the rolled plate is prepared, the sheet material may be prepared by conducting cold-pack rolling, but not hot rolling, cold rolling, and cross rolling, which are conventionally used, in order to avoid a roll lifting phenomenon.

(22) For example, when hot rolling is applied to the preparation of the sheet material, grains increase in size with increasing of the cycles of rolling, thus reducing the elongation.

(23) When typical cold rolling is applied to the preparation of the sheet material, it may be difficult to make a sheet 0.5 mm or less in thickness due to a roll lifting phenomenon caused by a repulsive force of the substance.

(24) In addition, when cross rolling is applied to the preparation of the sheet material, the elongation decreases as the size of the grains is excessively reduced by shear strain, with the resultant insignificant effect of formability.

(25) In this embodiment, therefore, 4 to 6 copies of the rolled plate are stacked and rolled at 100° C. or less and preferably at room temperature to prepare a sheet material having a thickness of 0.5 mm or less, preferably 0.2 mm or less.

(26) In the thermal treating method, limitation is made of the thermal treatment temperature is limited to the range of 350° C.-400° C. and thermal treatment time is limited to the range of 30-60 minutes in order to control the growth of grains and textures. When the thermal treatment temperature and time are deviated from the condition, a desired pattern of textures is not formed, or desired strength and elongation cannot be obtained because grains increase.

(27) Hereinafter, the present disclosure is explained with reference to Examples and Comparative Examples.

(28) The molten metals produced with various contents of components as shown in Table 1, below, were subjected to extrusion, cold rolling, cold-pack rolling, and thermal treatment.

(29) In detail, the molten metals with various contents of the components as in Table 1 were cast and the as-cast materials were extruded and cold rolled. Four copies of the rolled plate in a sheet form were stacked and subjected cold-pack rolling. In this regard, the rolling was conducted 8 times to afford a sheet material 0.2 mm thick.

(30) The 0.2-mm-thick sheet material thus prepared was thermally treated at 350° C. for 60 min and then measured for yield strength, tensile strength, and elongation. The results are summarized in Table 1.

(31) TABLE-US-00001 TABLE 1 Yield Tensile Ex. # Mg Mn Cr Strength Strength Elongation C. Example 1 6 — — 128.2 302.5 20.7 C. Example 2 7 — — 146.1 323.4 24.1 C. Example 3 8 — — 158.2 345.0 23.4 Example 1 9 — — 157.1 362.8 30.4 Example 2 10 — — 159.3 369.3 31.7 C. Example 4 2 0.12 0.12 61.9 168.8 17.5 C. Example 5 4 0.12 0.12 116.9 244.7 21.3 C. Example 6 5 0.12 0.12 146.5 301.8 25.0 C. Example 7 6 0.12 0.12 162.5 315.7 25.3 C. Example 8 7 0.12 0.12 150.0 346.7 25.6 C. Example 9 8 0.12 0.12 175.3 382.5 27.7 Example 3 9 0.12 0.12 166.7 361.2 30.2 Example 4 10 0.12 0.12 174.5 377.9 31.3 C. Example 10 12 0.12 0.12 160.5 343.5 27.8

(32) As is understood from the data of Table 1, the sheet materials of the Examples which met kinds and contents of the alloy components proposed in the present disclosure all exhibited a yield strength of 150 MPa or higher, a tensile strength of 360 MPa or higher, and an elongation of 28% or higher.

(33) Particularly, Examples 3 and 4, which contained Mn and Cu, were superior in terms of yield strength and elongation to Examples 1 and 2, which do not contain Mn and Cu.

(34) In addition, Comparative Examples 1, 2, 4, 5, and 6, which included Mg at a content less than that proposed in the present disclosure, were observed to be lower in all yield strength, tensile strength, and elongation, compared to the Examples.

(35) Comparative Examples 3 and 9, which had a Mg content slightly lower than that proposed in the present disclosure, exhibited higher yield strength and tensile strength, but lower elongation than the Examples.

(36) Furthermore, Comparative Example 10 that had a Mg content higher than that proposed in the present disclosure exhibited yield strength similar to or higher than those of the Examples, but was rather lower in elongation than the Examples.

(37) Next, experiments were conducted to examine grain sizes, texture formation, and formability (LDH) according to thermal treatment conditions for the sheet material.

(38) Sheet materials having the composition of Example 4 in Table 1 were prepared and subjected to thermal treatment as indicated in Table 2. The specimens thus obtained were measured for grain size, texture state, and formability and the results are summarized in Table 2 and depicted in FIGS. 1 and 2.

(39) FIG. 1 shows texture states according to manufacturing steps and thermal treatment conditions, and FIG. 2 shows orientation distribution function analysis results according to thermal treatment conditions.

(40) TABLE-US-00002 TABLE 2 Thermal treatment condition 200° C. 250° C. 300° C. 350° C. 400° C. 400° C. BA 30 min 30 min 30 min 30 min 30 min 120 min Texture Copper, Brass, Cube Cube, R-Cube Cube, R-Cube S, Goss Formability (LDH) 3.1 mm 4.2 mm 6.5 mm 7.0 mm 7.3 mm 7.4 mm —

(41) As shown in FIG. 1, the thermal treatment made the grains fine to the level as small as 22-25 μm.

(42) From the data of Table 2 and FIG. 2, the thermal treatment induced the formation of cube texture and R-cube (rotated cube) texture, leading to increasing the elongation and enhancing the formability.

(43) At a temperature lower than that proposed herein, however, grains were neither made fine, nor was R-cube (rotated cube) formed.

(44) In addition, a thermal treatment time longer than that proposed herein decreased the elongation rather, and thus deteriorated the formability.

(45) FIGS. 3A and 3B are electron microscopic images of the specimens of Comparative Example 1 and Example 1 in Table 1, respectively.

(46) As shown in FIG. 3A, the formation of precipitates did not occur for Comparative Example 1.

(47) In contrast, precipitates were observed and identified as Al.sub.3Mg.sub.2 as shown in FIG. 3B.

(48) Therefore, it was found that Al.sub.3Mg.sub.2 precipitated in the atomic solution with the increase of Mg content, contributing to an improvement in strength and formability.

(49) Although the exemplary embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope of the accompanying claims.

(50) As described hitherto, according to an embodiment of the present disclosure, an aluminum-based separator superior in terms of yield strength and elongation can be manufactured and used, in substitution for stainless steel-based separator, in fuel cell stacks, thus making the fuel cell stacks light without a functional decrease in the fuel cell stacks.