Abstract
Electrochemically-deposited polymer-metal composites, although explored for various uses, have only recently attracted attention for metallic bipolar plates used in fuel cells. Utilising a facile electrochemical deposition process, composite polyaniline and titanium nitride nanoparticle (PANI-TiN) coatings of varying thickness (5–50 cyclic voltammetry cycles) and composition (TiN nanoparticle concentration, 0.1 g L−1 and 0.5 g L−1) were deposited on stainless steel 304L (SS304) substrates. As compared to the pristine PANI coatings, which displayed an interfacial contact resistance (ICR) value of 367.5 mΩ cm2 and corrosion resistance (Ecorr) of 214 mVSHE, the composite PANI-TiN0.5 coatings displayed significantly reduced ICR values of 32.6 mΩ cm2 while maintaining similar corrosion resistance. The superior properties of these thin (~10 nm) composite coatings with low TiN loading (0.05–0.1 mg cm−2) show potential for further improvement in ICR with the possible use of higher TiN (or slightly lower PANI) concentrations. The study also demonstrated an interesting dynamic between PANI and TiN simultaneous deposition where the concentration of TiN NPs negatively affects the deposition rate for PANI, allowing the deposition of even thinner PANI coatings and possibly enabling control over the composition of the composite coating. The TiN NPs not only impart better conductivity for use as bipolar plates but, at higher loading, also assist PANI in enhancing corrosion resistance. Even for the lowest number of coating cycles (five cycles), the PANI-TiN0.5 composite films showed a remarkable 48 mV shift towards more positive/higher corrosion potential (Ecorr = 5 mVSHE) with respect to PANI (Ecorr = −57 mVSHE). The coatings demonstrated a reduction in corrosion current density to values of ~0.5 µA cm−2 achieving beyond the DoE 2020 target of 1 µA cm−2.
Highlights
Tremendous efforts are being made on a worldwide scale to improve the commercial and economic viability of alternative energy systems, like polymer electrolyte fuel cells (PEFCs), to replace the conventional combustion engine in the automotive industry
Different composite coatings consisting of polyaniline and titanium nitride nanoparticles (PANI-TiN) with variable TiN NP loadings were successfully deposited electrochemically on stainless steel (SS304) for application in bipolar plates for PEFCs
Interfacial contact resistance (ICR) and corrosion behaviour studied for the coated samples revealed that the introduction of small amounts of TiN NPs into PANI coating enabled significant enhancement in the electrical conductivity thereby reducing the interfacial contact resistance (ICR) values for the composite coatings
Summary
Tremendous efforts are being made on a worldwide scale to improve the commercial and economic viability of alternative energy systems, like polymer electrolyte fuel cells (PEFCs), to replace the conventional combustion engine in the automotive industry. The use for depositing polymer-metal composites (such as PANI-TiO2 and PANI-AuNP) as electronically conducting, corrosion resistant coatings on metallic BPP for use in fuel cells have only recently gained attention and demonstrated promising results [32,33,34]. Such composite coatings combine the advantages of corrosion-tolerant polymers with conductive metallic coatings. Composite coatings of PANI and TiN NPs (PANI-TiN) on SS304 were explored in order to further lower the costs of the coating deposition while retaining the ICR and enhanced corrosion resistance of polymer-metal composite coatings. PANI deposition rate during the cyclic voltammetry-based coating process
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