Design and optimization of electrolyte flow fields in electrochemical machining of cross-channel array with tool vibration

A metallic interconnect plate with a flow channel array is one of the most important elements in a solid oxide fuel cell (SOFC). Electrochemical machining (ECM) is considered to be an adoptable technology for fabricating flow channels in an interconnect plate on account of its efficiency and low cost. With respect to the traditional electrolyte flow mode in ECM cross-channel array, the electrolyte usually flows from one side to the opposite side of the rectangular processing area. However, obvious flow marks are typically formed at the bottom of channels perpendicular to the flow. According to multiphysical simulation analysis, the low electrolyte velocity in the channels perpendicular to the flow leads to uneven distribution of electrolyte products. To improve the uniformity of the flow field, two new electrolyte flow modes, “two-in and two-out” and “three-in and one-out”, are proposed. By adding one or two additional electrolyte inlets to the sides of the traditional flow field, the electrolyte flow velocity in the channels perpendicular to the traditional flow will be increased. Corresponding simulations and experiments were performed and the results showed that the “three-in and one-out” flow mode can produce a flatter bottom surface for the cross-channel array. Parameter optimization experiments for the preferred flow mode were undertaken and the optimal flow field parameters were determined.