In this work, we report a comprehensive study on a magnesium phosphate cement (MPC) based composite as the construction material for high performance bipolar plates of fuel cells. MPC with partial replacement of fly ash was employed as the binding matrix. Some carbon-based materials, such as graphite, carbon black, carbon fiber, and multi-walled carbon nanotubes were used to construct the conductive phase. A simple hot-press process was applied to produce the composite. The formula and the structure of the composite was modified and adjusted to optimize the properties of the composite to meet the US DOE 2015 technical targets, including the introducing of a reinforcement support. Finally, all the technical targets such as electrical conductivity (>100 S cm-1), the flexural strength (>25 MPa), the corrosion resistance ( < 1 μA cm-2), and gas permeability ( < 10-5 cm3 (s cm2)-1) were achieved as well as low cost ( < 5 $ per kW). The optimized formula and the detailed procedures to fabricate the MPC based composite were concluded.


Civil, Architectural and Environmental Engineering

Keywords and Phrases

Carbon Black; Carbon Fibers; Cements; Conductive Materials; Corrosion Resistance; Fly Ash; Fuel Cells; Gas Permeability; Magnesium; Magnesium Printing Plates; Phosphates; Plates (Structural Components); Yarn; Bipolar Plates; Carbon Based Materials; Conductive Phase; Electrical Conductivity; Magnesium Phosphate Cement; Partial Replacement; Press Process; Technical Target; Multiwalled Carbon Nanotubes (MWCN); Carbon Black; Carbon Fibers; Cement; Composites; Fly Ash; Fuel Cells; Hot Presses; Magnesium Compounds

International Standard Serial Number (ISSN)


Document Type

Article - Journal

Document Version

Final Version

File Type





© 2016 Royal Society of Chemistry, All rights reserved.

Publication Date

01 Jun 2016