Bipolar plates are critical components in high-efficiency energy conversion devices such as electrolyzers, fuel cells, and flow batteries, and their durability directly affects the overall performance and lifespan of the system. Although graphite bipolar plates exhibit excellent electrical conductivity and corrosion resistance, their inherent brittleness and porous structure render them prone to thermal-stress-induced damage under dynamic temperature conditions. In this study, a self-designed thermal shock testing system was utilized to perform 16,000 cycles of accelerated aging tests on graphite bipolar plates, alternating between high-temperature (90 °C) and low-temperature (30 °C) water bath environments. Systematic analysis was conducted on the performance degradation behaviors under such thermal cycling conditions using multi-scale characterization techniques, including scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electrical conductivity, contact angle, surface roughness, and corrosion current density analysis. The results demonstrate that the degradation in electrical conductivity, loss of hydrophobicity, and increased surface roughness were primarily attributed to thermal-stress-induced microcrack initiation and propagation, surface oxidation, and physical structural deterioration. Notably, the corrosion current density did not increase significantly after 16,000 thermal cycles, but slightly decreased in the later stage, indicating that the aging of graphite bipolar plates is dominated by physical fatigue damage, and the graphite matrix has excellent chemical stability. The novelty of this study lies in the construction of a thermal shock testing system under long-cycle conditions, revealing the synergistic mechanism of thermal cycle-induced performance degradation of graphite bipolar plates, which provides experimental evidence and theoretical guidance for the material selection, structural design, and protection strategies of highly durable bipolar plates.
Jiao et al. (Tue,) studied this question.