Integrated Experimental–Analytical Approach for ICR Minimization and Clamping Force Prediction in PEM Fuel Cells

ABSTRACT Interfacial contact resistance (ICR) critically affects the performance of proton exchange membrane (PEM) fuel cells, being governed by interfacial pressure, surface morphology, and bipolar plate (BPP) properties. This study presents a coating‐specific, data‐driven approach to predict clamping force by linking electrical response with contact pressure and BPP structural integrity. ICR, rib‐to‐pitch ratio, and contact pressure were systematically evaluated for three coatings (C01, C02, C03) and multiple rib‐to‐pitch configurations. C01 achieved the lowest ICR (<10 mΩ‐cm 2 ) at 1.90 ± 0.12 MPa, outperforming C02 (2.24 ± 0.62 MPa) and C03 (2.98 ± 0.11 MPa). The optimal rib‐to‐pitch ratio was 0.1667, with predicted clamping forces of 1716 N (C01), 2154 N (C02), and 2738 N (C03). The C01‐coated BPP delivered the highest peak power density of 0.425 W/cm 2 at 0.4 V. This integrated experimental–analytical framework provides a robust methodology for BPP structural optimization and precise cell clamping force prediction, supporting improved PEM fuel cell performance and efficiency.