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<p>Pulsed laser welding of 0.1-mm-thick 446 ferritic stainless steel for proton exchange membrane fuel cell (PEMFC) metallic bipolar plates was optimized through orthogonal experimentation and comprehensive balance analysis. The optimal parameters—laser power 60&#xa0;W, welding speed 80&#xa0;mm/s, defocus 0&#xa0;mm, and duty cycle 40%—achieved low heat input (~&#xa0;0.2&#xa0;J/mm), resulting in refined weld-zone grains (36.2&#xa0;<i>μ</i>m), shear strength of 480&#xa0;MPa (93% of base metal), and post-weld deformation of 207&#xa0;<i>μ</i>m. Four activating fluxes (CeO<sub>2</sub>, TiO<sub>2</sub>, SiO<sub>2</sub>, and Y<sub>2</sub>O<sub>3</sub>) were further investigated. TiO<sub>2</sub> yielded the most significant improvements: enhanced penetration while retaining semi-penetration morphology, finest grain size (14.31&#xa0;<i>μ</i>m), minimal deformation (154&#xa0;<i>μ</i>m), highest shear strength (485.8&#xa0;MPa, equivalent to base metal), and superior corrosion resistance in simulated PEMFC cathode environment (lowest i_corr of 1.102&#xa0;<i>μ</i>A/cm<sup>2</sup> and widest passivation range). These benefits stem from Ti(C, N) particle pinning, promoted heterogeneous nucleation, and formation of a dense, self-healing passive film. This work demonstrates that TiO<sub>2</sub> activating flux effectively mitigates grain coarsening and performance degradation, offering a practical, coating-free welding strategy for high-performance ultra-thin ferritic stainless steel bipolar plates.</p>

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Grain Refinement and Performance Optimization of Pulsed Laser-Welded 0.1-mm 446 Ferritic Stainless Steel Using Activating Flux for PEMFC Applications

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Peng Duan,
  • Ziqiang Yin,
  • Xin Yao,
  • Dongxu Hou,
  • Yuan Ren,
  • Zhen Xiao,
  • Fengxi Li,
  • Shouren Wang

摘要

Pulsed laser welding of 0.1-mm-thick 446 ferritic stainless steel for proton exchange membrane fuel cell (PEMFC) metallic bipolar plates was optimized through orthogonal experimentation and comprehensive balance analysis. The optimal parameters—laser power 60 W, welding speed 80 mm/s, defocus 0 mm, and duty cycle 40%—achieved low heat input (~ 0.2 J/mm), resulting in refined weld-zone grains (36.2 μm), shear strength of 480 MPa (93% of base metal), and post-weld deformation of 207 μm. Four activating fluxes (CeO2, TiO2, SiO2, and Y2O3) were further investigated. TiO2 yielded the most significant improvements: enhanced penetration while retaining semi-penetration morphology, finest grain size (14.31 μm), minimal deformation (154 μm), highest shear strength (485.8 MPa, equivalent to base metal), and superior corrosion resistance in simulated PEMFC cathode environment (lowest i_corr of 1.102 μA/cm2 and widest passivation range). These benefits stem from Ti(C, N) particle pinning, promoted heterogeneous nucleation, and formation of a dense, self-healing passive film. This work demonstrates that TiO2 activating flux effectively mitigates grain coarsening and performance degradation, offering a practical, coating-free welding strategy for high-performance ultra-thin ferritic stainless steel bipolar plates.