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With these considerations in mind three processes were chosen to fabricate mold surfaces; milling, turning, and grinding. These methods will provide different surfaces, as well as generate a moderately flat surface. Mold material selection was important due to the possible transfer of the material from the mold to the Nafion if the metal were to oxidize. This is why aluminum 6061-T6 1.25 in. round was used for the molds. Aluminum provides good resistance to corrosion, and it is an easy metal to machine allowing for many different types of surface finishes to be applied to it. The first step in preparation of the molds was to take the long bar stock and trim it down to size. The lathe was used to face each mold and then part off the mold at about nine tenths of an inch for the height of each mold. Each surface finish must have two molds of that surface made, one for the top surface of the Nafion and one for the bottom surface of the Nafion. Molds- Milled Milled molds were fabricated using a Haas Mini Mill, a Computer Numerical Controlled (CNC) mill. The tool that was used for each milled part was a tri-insert facing mill. The tool feeds and speeds were the variable that changed to create the different surface finishes; Table 1 has the feeds and speed information used for the sets of milled molds. Then a small chamfer was completed to remove the burrs from the edges of the faced surface. Mold Set M1 M2 M3 z-feedrate [PM] 25.305 101.22 45 180 45 90 Speed [RPM] 3374 6000 6000 Depth of cut [in] 0.05 0.05 0.05 xy-feedrate [PM] Table 1 – Feedsrates, Speeds, and Depth of cut for the milled mold sets. 11PDF Image | surface roughness of the Nafion membrane in a PEM fuel cell
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