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Corrosion resistance of coated aluminum bipolar plates for proton exchange membrane fuel cells
Department of Electrical Engineering, Division of Solid-State Electronics, Uppsala University, Uppsala, 751 03, Sweden.
RISE Research Institutes of Sweden.ORCID iD: 0000-0001-6332-0501
RISE Research Institutes of Sweden, Safety and Transport, Electrification and Reliability.ORCID iD: 0000-0002-2788-960x
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2025 (English)In: Electrochimica Acta, ISSN 0013-4686, E-ISSN 1873-3859, Vol. 539, article id 146966Article in journal (Refereed) Published
Abstract [en]

Aluminum is a very attractive material for bipolar plates in proton exchange membrane (PEM) fuel cells due to its low weight, excellent thermal and electrical conductivity, as well as good recyclability. However, to achieve the necessary low contact resistance and corrosion stability, a suitable surface coating is needed. In the present study, two different material systems were evaluated, electroless deposited NiP based coatings and high-power impulse magnetron sputter-deposited (HiPIMS) Ti based coatings. The addition of a 100 nm amorphous carbon (a-C) top-layer on the NiP and Ti based coatings was also evaluated. The electrochemical corrosion behavior of the coatings was evaluated in simulated PEM environments. Potentiodynamic and potentiostatic polarization experiments revealed that the HiPIMS Ti coatings performed better than NiP coatings. The addition of the a-C top-layer on the other hand was found to be detrimental to the Ti based coatings resulting in a corrosion current density of 3.6 µA/cm2. The opposite was observed in the case of the NiP based coatings where the addition of the a-C layer decreases the corrosion current thereby increasing corrosion resistance. Further analysis showed that defects in the coating as well as the presence of a Fe-Si rich particles in the Al substrate were the initiation points for the corrosion attacks to occur.

Place, publisher, year, edition, pages
Elsevier Ltd , 2025. Vol. 539, article id 146966
Keywords [en]
Bipolar plates, Coatings, Contact resistance, Corrosion, PEM fuel cell, Aluminum, Aluminum coatings, Aluminum corrosion, Amorphous carbon, Corrosion resistance, Corrosion resistant coatings, Corrosive effects, Electrochemical corrosion, Iron alloys, Magnetron sputtering, Nickel compounds, Nickel-Phosphorus, Phosphorus compounds, Silicon compounds, Aluminum bipolar plates, Bipolar-plates, Carbon top layers, Contact resistance stability, Electrical goods, High power, Proton-exchange membranes fuel cells, Recyclability, Thermal and electrical conductivity, Ti-based, Proton exchange membrane fuel cells (PEMFC)
National Category
Surface- and Corrosion Engineering
Identifiers
URN: urn:nbn:se:ri:diva-79352DOI: 10.1016/j.electacta.2025.146966Scopus ID: 2-s2.0-105013101649OAI: oai:DiVA.org:ri-79352DiVA, id: diva2:2017321
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Article; Granskad

Available from: 2025-11-28 Created: 2025-11-28 Last updated: 2025-11-28Bibliographically approved

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Törne, KarinMølmen, LiveLundblad, Anders

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Gangaprasad Rao, SmitaTörne, KarinMølmen, LiveNederstedt, HannesLundblad, Anders
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RISE Research Institutes of SwedenElectrification and Reliability
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Electrochimica Acta
Surface- and Corrosion Engineering

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