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This study aims to improve the forming process of metallic bipolar plates using magnetorheological elastomers (MREs) to enhance formability.

Extended forming depth and thickness uniformity of metallic bipolar plate under variable magnetic field path in magnetorheological elastomer assisted forming

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Randomized trial demonstrates enhanced forming depth and thickness uniformity in bipolar plates, indicating improved manufacturability.

This study aims to improve the forming process of metallic bipolar plates using magnetorheological elastomers (MREs) to enhance formability.
Flexible-die forming method utilizing MREs with adjustable magnetic field path.
MREs with 20% ferromagnetic particle content and flux intensity of 1850 Gs were employed.
The two-stage magnetic field path was tested to control the forming load differentially.
Forming depth limit increased by 12.8% and effective flow area by 17.6% using MREs compared to conventional techniques.
Shell thickness uniformity improved by 21% due to the modified magnetic field path.
Ductile fracture characteristics were observed on the fracture surfaces of the bipolar plates.

ZHU et al. (2026) studied this question.

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