Low Interfacial Contact Resistance Research Articles

Microstructural Characterization of Porous Transport Layer Coatings

The porous transport layer (PTL) is a key component in polymer electrolyte membrane (PEM) water electrolyzers and serves the role of controlling the transport of reactants and products to and from the anode. Maintaining a low interfacial contact resistance between the titanium (Ti) fiber or sinter PTL and the iridium (Ir) anode catalyst is critical to maintaining the performance of the electrolyzer cell. This requires costly precious metal coatings, typically Pt, to inhibit the formation of native oxide layers during long-term cell operation. Strategies to reducing the thickness of these costly coatings including surface treatments, such as etching and abrasion, alternative low-cost coating materials, and implementation of microporous layers. It is crucial to understanding the morphologies and degradation mechanisms of these new strategies in order to accelerate the development of cheaper, more robust PTL coatings.In this work, correlative ex situ characterization methods, including laser confocal microscopy (LCM), focused ion beam (FIB), scanning electron microscopy (SEM), time-of-flight secondary ion mass spectrometry (ToF-SIMS), atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS) and scanning transmission electron microscopy (STEM), are utilized to explore the impact surface treatments, such as etching and abrasion, on the Pt coatings uniformity and surface roughness. The thickness, local topography, and continuity of the Pt coating were quantified and correlated with interfacial contact resistance and electrochemical cell performance measurements. Changes to the thickness and composition of the coatings and oxide layers after single-cell tests will also be reported. Overall, these findings aim to guide the development of PTL treatments and coatings, ensuring the creation of highly durable and efficient PEM water electrolyzers that align with the U.S. Department of Energy's Hydrogen Shot goal of reducing the cost of clean hydrogen production to $1 per kilogram by 2031.Funding for this work was provided by U.S. Department of Energy Office of Energy Efficiency and Renewable Energy, Hydrogen and Fuel Cell Technologies Office through the H2NEW Consortium. Electron microscopy research conducted as part of a user project at the Center for Nanophase Materials Sciences (CNMS), which is a US Department of Energy, Office of Science User Facility at Oak Ridge National Laboratory.

Carboxymethyl Cellulose – Polyvinyl Alcohol Composite-Based Gel Polymer Electrolyte for Rechargeable Zn-Air Batteries

The high ionic conductivity, lower interfacial contact resistance, enhanced safety, non-toxicity, and biodegradability bring the gel polymer electrolytes (GPEs) as a prospective electrolyte for applications in high-energy density flexible Zn-air batteries (ZABs). The present study comprehensively optimizes the procedures to obtain carboxymethyl cellulose (CMC)–polyvinyl alcohol (PVA) composite-based GPEs holding a maximum KOH amount in the polymer matrix. Optimization of the GPE has been performed and demonstrated by an in-house-developed rechargeable ZAB cells using MnO2-based air cathode and Zn anode. The optimization parameters include the ratio of PVA:CMC, concentration of PVA-CMC in DI water, and thickness of the gel polymer electrolyte. Results show that a 4mm thick GPE prepared from a polymer membrane synthesized using PVA:CMC ratio of 5:2 at a concentration of 0.063 g ml−1 in DI water displayed the highest 6M KOH uptake, least charge transfer resistance of the device, higher discharge plateau, and 5–6 times more cycling compared to GPE made of PVA only. The “as-synthesized GPE” demonstrates high stability of GPE over 100h for a Zn-air battery device. The findings of this work shall speed up the development of Zn air batteries for applications as energy storage systems.

Effect of the graphene-based material on the conductivity and corrosion behaviour of PTFE/graphene-based composites coatings on titanium for PEM fuel cell bipolar plates

Titanium is widely used as a material for bipolar plates (BP) PEM fuel cells, but they require conductive coatings that help with corrosion and have low interfacial contact resistance (ICR). Among many materials, polymer composites reinforced with graphene nanoparticles have the potential to become an effective coating, but the influence of different types of graphene-based materials on the performance remains has not been properly established. In this study, different nanoparticles (graphene monolayers, reduced graphene oxide and few-layer graphene) were used to process PTFE/graphene composite coatings for Ti, and their performance was evaluated. Most of the coating formulations improved the corrosion resistance of the Ti in one or two orders of magnitude, but only the combination of few-layer graphene and carbon black as additive resulted in an ICR of 12 mΩcm2, in range with the target values.

COMPOSITE MATERIALS BASED ON THERMALLY EXPANDED GRAPHITE FOR BIPOLAR PLATES OF FUEL CELLS

Composite materials based on a thermosetting binder and thermally expanded graphite with a filler content of 50-70% were obtained by hot pressing. The influence of the method of introducing the filler into the composite on its physical, mechanical and electrochemical characteristics has been studied. Materials obtained by mixing air-dry components are characterized by high electrical conductivity (up to 195 S/cm) and strength properties (more than 25 MPa), low interfacial contact resistance (less than 10 mΩ cm2) and a corrosion current not exceeding 1 μA/cm2, which will allow ensure high efficiency of energy conversion in PEM FC.

Bias Voltage Dependency of Structural and Bipolar Plate-Related Properties of Cathodic Arc-Deposited Carbon-Based Coatings.

Carbon-based coatings composed of a chromium interlayer and a carbon top layer were deposited on stainless steel substrates via cathodic arc evaporation. During the carbon deposition, the bias voltage was varied between 900 and 1 V to investigate the influence on the structural, electrical, and electrochemical properties. Raman spectroscopy indicated a dependency of the intensity ratio and G peak position on the bias voltage, which can be attributed to an alteration of the structure. Transmission electron microscopy (TEM) cross-section investigations revealed a graphite-like structure for most carbon top layers but with an increasing amount of disordered fractions, eventually resulting in an amorphous structure at 1 V. To further examine the structure, electron energy loss spectroscopy (EELS) was used. In the high-loss region, distinct π* and σ* peaks could be observed, which agree well with the TEM results. Additionally, analysis of the low-loss region showed that the 1 V carbon top layer exhibits a shifted σ plasmon peak at 20 eV corresponding to an amorphous structure. The carbon-based coatings are highly conductive with low interfacial contact resistance values between 4 and 1.5 mΩ cm2 at 150 N cm-2. From a bias voltage of 200 V, the resistance increases. To evaluate the corrosion resistance, we conducted potentiodynamic polarization tests. At first, with decreasing bias voltage, the corrosion resistance increases and then decreases for both the 100 and 1 V samples. Considering the low thickness, the coating with a carbon top layer deposited at 600 V had the best corrosion resistance. In combination with the excellent contact resistance, the 600 V sample is a highly suitable coating for metallic bipolar plates.

Effects of Nitrogen Flow Rate on the Performances of Cathodic Arc Deposited TiN Films on 316L Stainless Steels as Bipolar Plates for the Proton‐Exchange Membrane Fuel Cell

The corrosion resistance, interfacial contact resistance (ICR), and hydrophobicity of cathodic arc deposited TiN films on 316L stainless steels at different nitrogen flow rates as bipolar plates (BPs) for the proton‐exchange membrane fuel cell (PEMFC) are investigated. It is shown in the results that the TiN‐coated 316L stainless steel prepared at a moderate nitrogen flow rate (250 sccm) exhibits a low stable corrosion current density of 6.5 × 10−8 A cm−2 in the simulated corrosive cathode environment of PEMFC, and a low ICR of 8.94 mΩ cm−2 at a pressure of 1.38 MPa after corrosion, meanwhile presents a good hydrophobicity before and after corrosion. These results are discussed by considering the probable effects of the nitrogen flow rate on the substrate/coating system based on the microstructural characterization of the substrate/coating interface and the coating, which shows that the interdiffusion will be started in the deposition process and a moderate nitrogen flow rate during the coating process will promote to the broadening of interface region and lead to the formation of a robust and high‐quality coating with fewer defects that can effectively improve the performances of the 316L stainless steel substrate as the BP for PEMFC.

Semitransparent organic solar cells based on low temperature processed PEIE as electron transport layer with enhanced charge transfer ability

In inverted structure-based semitransparent organic solar cells (OSCs), the electron transport layer (ETL) plays a crucial role in the improvement of the transparent cathode efficiency in collecting and extracting negative charge carriers. Zinc oxide (ZnO) thin film prepared by zinc acetate dihydrate precursor with various benefits is generally used as ETL. However, high temperature, less charge transfer ability, and irregular film surface due to fiber-like domain formation limit the device performance. In this work, a new approach is presented by using low-temperature processed polyethylenimine ethoxylated (PEIE) as ETL in semitransparent OSCs fabricated in an ambient environment with a blend of low-bandgap donor polymer PTB7-Th, and fullerene acceptor, PC71BM, based active layer. For semitransparent OSCs, the thickness of the silver electrode has been varied from 55 nm to 25 nm to investigate its effect on the electrical and optical properties of the devices. The power conversion efficiencies (PCE) of 5.1% and 4.6% were achieved for semitransparent devices (25 nm thickness of silver electrode) for PEIE and ZnO ETLs, respectively. Similarly, PCE of 7% and 6.7% have been achieved for opaque devices (85 nm thickness of silver electrode) using PEIE and ZnO ETLs, respectively. PEIE based devices with 25 nm Ag demonstrate about 25%–30% transparency. The impedance spectroscopy measurements indicate low interfacial contact resistance and fast charge transfer capability for PEIE interlayer-based devices compared to the ZnO based devices. The encapsulated semitransparent devices processed and stored in ambient conditions with PEIE and ZnO ETLs were found to retain ≈80% performance for up to 45 days.

Improvement in Corrosion Resistance and Interfacial Contact Resistance Properties of 316L Stainless Steel by Coating with Cr, Ti Co-Doped Amorphous Carbon Films in the Environment of the PEMFCs.

In order to obtain films with high corrosion resistance and excellent interfacial contact resistance (ICR) on 316L stainless steel used for bipolar plates in proton-exchange membrane fuel cells (PEMFCs), Cr, Ti co-doped amorphous carbon films were prepared on 316L stainless steel. The preparation method for the coating was magnetron sputtering. The doping amount of the Ti element was controlled by a Cr target and a Ti target current. The change in the structure and properties of the coating after the change from Cr single-element doping to Cr and Ti co-doping was studied. The change rule of the structure and properties of the coating from Cr single-element doping to Cr and Ti co-doping was studied. An increase in the Ti content led to a decreased grain boundary, a flatter surface, and a higher sp2-hybridized carbon content. TiC and CrC nanocrystals were formed in the amorphous carbon structure together. The amorphous carbon films doped with Cr and Ti simultaneously achieved a low ICR and high corrosion resistance compared with single-Cr-doped amorphous carbon. The enhanced corrosion resistance was attributed to the decreasing grain boundary, the formation of the TiC crystal structure, and the smaller grain size. The best performance was obtained at a Ti target current of 2A. Compared with bare 316L stainless steel, the corrosion resistance of Cr, Ti co-doped amorphous carbon (Icorr = 5.7 × 10-8 A/cm2, Ti-2 sample) was greatly improved. Because Ti doping increased the content of sp2-hybridized carbon in the coating, the contact resistance of the coating decreased. Moreover, the interfacial contact resistance was 3.1 mΩ·cm2 in the Ti-2 sample, much lower than that of bare 316L stainless steel. After the potentiostatic polarization test, the coating still had excellent conductivity.

Research Progress of Interfacial Design between Thermoelectric Materials and Electrode Materials.

Intensive efforts have been conducted to realize the reliable interfacial joining of thermoelectric materials and electrode materials with low interfacial contact resistance, which is an essential step to make thermoelectric materials into thermoelectric devices for industrial application. In this review, the roles of structural integrity, interdiffusion, and contact resistance in long-term reliabilities of thermoelectric modules are outlined first. Then interfacial reactions of near-room-temperature Bi2Te3-based thermoelectric materials and various electrode materials are reviewed comprehensively. We also summarized the joining behavior of the mid-temperature PbTe-based thermoelectric materials and commonly used electrode materials. Subsequently, for other thermoelectric materials systems, i.e., SiGe, CoSb3, and Mg3Sb2, previous attempts to join with some electrode materials are also recapitulated. Finally, some future prospects to further improve the joint reliability in thermoelectric device manufacturing are proposed. We believe that this review will provide guidance for preparing thermoelectric devices and optimizing thermoelectric device design.

Conductive Polymer and Nanoparticle-Promoted Polymer Hybrid Coatings for Metallic Bipolar Plates in Proton Membrane Exchange Water Electrolysis

Proton exchange membrane water electrolysis (PEMWE) is a green hydrogen production technology with great development prospects. As an important part of PEMWE, bipolar plates (BPs) play an important role and put forward special requirements due to the harsh environments on both the anode and cathode. Recently, metal-based BPs, particularly stainless steel and titanium BPs have attracted much attention from researchers all over the world because of their advantages of high corrosion resistance, low resistivity, high thermal conductivity, and low permeability. However, these metallic BPs are still prone to being oxidized and are facing with hydrogen embrittlement problems in the PEMWE working environment, which would result in reduced output power and premature failure of the PEMWE stack. In order to reduce the corrosion rate and maintain low interfacial contact resistance, the surface modification of the metallic BPs with protective coatings, such as precious metals (e.g., Au, Pt, etc.) and metal nitrides/carbides, etc., have been extensively investigated. However, the above-mentioned coating materials are restricted by the high-cost materials, complex equipment, and the complicated operation process. In this review, the surface modification of metallic BPs based on silane treatment, conductive polymers, e.g., polyaniline (PANI) and polypyrrole (PPy) as well as some nanoparticles-promoted polymer hybrid coatings which have been investigated for PEMWE, are summarized and reviewed. As for the silane treatment, the dense silane can not only effectively enhance the corrosion resistance but also improve the adhesion between the substrate and the conductive polymers. As for PANI and PPy, the typical value of corrosion current density of a PANI coating is 5.9 μA cm−2, which is significantly lower than 25.68 μA cm−2 of the bare metal plate. The introduction of nanosized conductive particles in PANI can further reduce the corrosion current density to 0.15 μA cm−2. However, further improvement in the electrical conductivity is still desired to decrease the interface contact resistance (ICR) to be lower than 10 mΩ cm2. In addition, serious peeling off of the coating during long-term operation also needs to be solved. Typically, the conductive polymer reinforced by graphene, noble metals, and their compounds in the form of nanoparticle-promoted polymer hybrid coatings could be a good choice to obtain higher corrosion resistance, durability, and conductivity and to extend the service life of PEMWE. Especially, nanoparticle-promoted polymer hybrid coatings consisting of polymers and conductive noble metals or nitrides/carbides can be controlled to balance the conductivity and mechanical properties. Due to the advantages of a simple preparation process, low cost, and large-scale production, nanoparticle-promoted polymer hybrid coatings have gradually become a research hotspot. This review is believed to enrich the knowledge of the large-scale preparation process and applications of BPs for PEMWE.

Polarization-tunable interfacial properties in monolayer-MoS2 transistors integrated with ferroelectric BiAlO3(0001) polar surfaces.

With the explosion of data-centric applications, new in-memory computing technologies, based on nonvolatile memory devices, have become competitive due to their merged logic-memory functionalities. Herein, employing first-principles quantum transport simulation, we theoretically investigate for the first time the electronic and contact properties of two types of monolayer (ML)-MoS2 ferroelectric field-effect transistors (FeFETs) integrated with ferroelectric BiAlO3(0001) (BAO(0001)) polar surfaces. Our study finds that the interfacial properties of the investigated partial FeFET devices are highly tunable by switching the electric polarization of the ferroelectric BAO(0001) dielectric. Specifically, the transition from quasi-Ohmic to the Schottky contact, as well as opposite contact polarity of respective n-type and p-type Schottky contact under two polarization states can be obtained, suggesting their superior performance metrics in terms of nonvolatile information storage. In addition, due to the feature of (quasi-)Ohmic contact in some polarization states, the explored FeFET devices, even when operating in the regular field-effect transistor (FET) mode, can be extremely significant in realizing a desirable low threshold voltage and interfacial contact resistance. In conjunction with the formed van der Waals (vdW) interfaces in ML-MoS2/ferroelectric systems with an interlayer, the proposed FeFETs are expected to provide excellent device performance with regard to cycling endurance and memory density.

Evaluation of anticorrosion and contact resistance behavior of poly(orthophenylenediamine)- coated 316L SS bipolar plate for proton exchange membrane fuel cell

The present work was focused on the corrosion properties and contact resistance behavior of poly(orthophenlyenediamine) (PoPD) coating on 316L SS bipolar plates. To reduce the corrosion rate and increase the interfacial conductivity of 316L SS bipolar plates, PoPD coating was deposited using an electropolymerization technique by the various monomer concentration of orthophenlyenediamine (oPD) on its surface. The presence of 1, 2, 4, 5- tetra substituted benzene nuclei of phenazine units in the polymer coating was confirmed by infrared spectroscopy. X-ray photoelectron spectroscopy analysis has confirmed the (%) of chemical composition in PoPD coating. The results of scanning electron microscopy analysis revealed that the uniform and compact coating with complete cover on 316L SS. The corrosion properties were investigated in 0.5 M H2SO4 and 2 ppm HF solution at 80 °C. The polarization test results showed that the PoPD coating reduced the corrosion current density both in the PEMFC anode and cathode environments. The charge transfer resistance values were in the order of 316L SS ˂ 0.02 M PoPD ˂ 0.06 M PoPD ˂ 0.04 M PoPD. A very low interfacial contact resistance and good adhesion strength was observed for 0.04 M PoPD coating. The higher contact angle of 0.04 M PoPD coating explained the hydrophobic property and more benefit of water management in the PEMFC environment. The results of the analysis of total metal ion releases clearly explained that the low level of metal ions released for 0.04 M PoPD coating. The overall studies revealed the PoPD coating with optimized 0.04 M oPD concentration showed best performance and provided more anodic protection to 316L SS bipolar plates.

Development of Corrosion Resistant and Electrically Conductive Coatings on Metallic Bipolar Plates for Applications in PEMFC

Proton exchange membrane fuel cell (PEMFC) is considered as one of the most promising alternative energy devices due to its high efficiency, low pollutants emission and possible application in automobiles. However, the application of PEMFC is still hindered by the high cost of some of its components such as bipolar plates (BPP) which are a key component in PEMFC to facilitate electron transfer, gas flow, heat and water removal. To reduce the cost, increase conductivity and durability, metallic bipolar plates, typically made of stainless steel, are normally used but they could suffer from severe corrosion in the acidic environment of PEMFC; the formation of corrosion products on the metal surface could reduce the through-plane electrical conductivity and increase the interfacial contact resistance (ICR) between the bipolar plates and gas diffusion layer, eventually causing high power loss in the fuel cell stack. Therefore, developing corrosion resistant and electrically conductive bipolar plates is of vital importance for the practical applications of PEMFC.Transition nitride coated stainless steel, such as titanium nitride (TiN) coated 316L SS, is considered as a possible solution to improve the performance metallic bipolar plates. In this work, TiN coated 316L SSs with heat treatment at different temperatures were prepared. The corrosion behaviours of the prepared samples were investigated in the simulated working environments of fuel cell. The heat treated samples exhibit the improved corrosion resistance compared with the pristine TiN coated samples and with an increase of the heat treatment temperature, the corrosion resistance tends to increase due to the formation of oxide and oxynitride on the sample surface. The ICR test results indicate that high temperature (450 ℃) heat treatment has detrimental effect on the electrical conductivity of samples due to the formation of a thick oxide dominated layer, while the samples heat treated at 300 ℃ only form the graded layers with suitable oxide amount which endows the coated specimens with a very low ICR value both before and after the corrosion tests.Moreover, TiN coatings with different amounts of Ta addition were also prepared. After the corrosion tests in the H2SO4 solution with pH=3 at 70 ℃, the results reveal that Ti150Ta30N samples exhibit the highest corrosion resistance compared with the pristine TiN coated samples and the samples with different amount of Ta addition. The steady state current density of Ti150Ta30N samples after long term potentiostatic polarization at 0.6 V (vs Ag/AgCl) is 0.02 μA/cm2 which is much lower than that of TiN coated samples. The Ti150Ta30N samples also presents a good electrical conductivity with low ICR values before and after the corrosion tests. These studies suggest that a suitable amount of oxygen or Ta incorporation into TiN is a feasible strategy to improve the corrosion resistance while maintaining considerable electrical conductivity of TiN samples.

Adjustable TiN coatings deposited with HiPIMS on titanium bipolar plates for PEMFC

TiN coatings were deposited by HiPIMS at different N2 flow rate to improve the corrosion resistance and conductivity of metallic bipolar plates. The results show that the surface microstructure of TiN coating depends strongly on the N2 flow rate, all the samples (N2 flow rate: 4 to10 sccm) meet the DOE 2025 standard and exhibit good hydrophobicity, which has great potential for industrial application. Among them, at the N2 flow rate of 8 sccm, the TiN coating shows high compactness and the optimum surface microstructure with the lowest surface roughness of 1.083 nm and the highest hardness of 31.172 GPa. The optimized TiN coating exhibits excellent corrosion resistance with corrosion current density of 0.278 μA cm−2 and a low interfacial contact resistance value of 3.51 mΩ cm2. This work has opened a new way for the large-scale preparation of high-performance metal bipolar plate coatings.

A Ti3C2Tx-carbon black-acrylic epoxy coating for 304SS bipolar plates with enhanced corrosion resistant and conductivity

A conducting and anticorrosive coating is crucial for the application of metal bipolar plates (BP) in proton exchange membrane fuel cell (PEMFC). In this work, a Ti3C2Tx (T)-carbon black (C)-acrylic epoxy (AE) coating is prepared on 304 stainless steel (SS) with enhanced corrosion resistance and conductivity. The corrosion resistance of the T-C-AE coating is investigated in a 0.5 M H2SO4 solution as compared to the AE, T, and T-AE coatings. The T-C-AE coated 304SS exhibits the strongest corrosion resistance with the most positive corrosion potential and the lowest corrosion current density of 0.00673 μA cm−2 in all the samples, while retaining intact and compact surface morphology with the lowest metal ion dissolution even after immersed for 720 h. The addition of Ti3C2Tx and carbon black into the AE matrix greatly decreases interfacial contact resistance (ICR), and the T-C-AE coating achieves a low ICR of 15.5 mΩ cm−2 under 140 N cm−2 compaction force. The excellent anticorrosion performance is mainly attributed to the physical barrier and the cathodic protection provided by the stacked Ti3C2Tx (MXene) nanosheets in the T-C-AE coating. This eco-friendly, conducting, and anticorrosive T-C-AE coating has a good application prospect on SS BP of PEMFC.

Surface Conductivity and Preferred Orientation of TiN Film for Ti Bipolar Plate

The properties of thin films are often influenced by the crystal’s preferred orientation. In the present study, we report the strong dependence of surface conductivity on the preferred orientation of TiN film that acts as the coating material for Ti bipolar plate. The preferred orientation of TiN film is successfully controlled along the (111) or (200) planes by adjusting the N2 flow rate or Ti substrate temperature during the deposition process via DC (direct current) reactive magnetron sputtering. Small N2 flow rate of 3 to 6 sccm or low substrate temperature (e.g., 25 °C) facilitates the growth of TiN films along the (111). The (111) preferred orientated TiN films show much lower interfacial contact resistance (ICR) than the (200) preferred orientated films. A considerably low ICR value of 1.9 mΩ·cm2 at 140 N/cm2 is achieved at the N2 flow of 4 sccm and the substrate temperature of 25 °C.

Modifying Ti-Based Gas Diffusion Layer Passivation for Polymer Electrolyte Membrane Water Electrolysis via Electrochemical Nitridation.

A gas diffusion layer represents an important element of collector and stack components used in polymer electrolyte membrane (PEM) water electrolyzers (WE). Nowadays, titanium-based gas diffusion layers (GDLs) have high stability and are frequently employed as anode GDLs, yet reliability issues emerging from passivation have limited their practical deployment. Hence, we develop an inexpensive way of producing high conductivity and corrosion resistance of Ti-based GDLs through electrochemical nitridation. The morphology and content of the nitride phase on the surface of the Ti felt GDL are efficiently regulated by adjusting reduction potential and reaction time. According to X-ray photoelectron spectroscopy studies, the modified Ti felt is coated with ammonium ions and nitrogen-incorporated oxides, namely, TiN/TiOx, on the surface. The nitride surface shows a low interfacial contact resistance (ca. 1.0 mΩ cm2 at 140 N/cm2) and excellent corrosion resistance (0.920 μA cm-2) in the simulated PEM WE environments. The electrochemical nitridation provides an economic way to introducing N layers on the surface of the Ti-based GDL with high performance, which is very promising for efficient PEM water electrolysis.

High corrosion resistance and surface conductivity of (Ti1-xCrx)N coating for titanium bipolar plate

(Ti1-xCrx)N coatings with high corrosion resistance and surface conductivity are developed for Ti bipolar plate. More Cr leads to lower surface conductivity but much higher corrosion resistance. The optimized (Ti0.48Cr0.52)N coating shows a low interfacial contact resistance of 5.1 mΩ cm2 at 140 N/cm2 and small current density of 0.45 μA/cm2 after 10 h corrosion test at 0.2 V vs. Hg/Hg2SO4 (0.5 M H2SO4 + 2 ppm HF, 80 °C with air), which is approximately 50 times lower than that (24 μA/cm2) for TiN. The improved corrosion resistance is majorly owing to the presence of CrOriched bond on the surface.

Superhydrophobic Cobalt–Graphene Composite for the Corrosion Protection of Copper Bipolar Plates in Proton Exchange Membrane Fuel Cells

Abstract Superhydrophobic cobalt and cobalt–graphene films were fabricated on copper bipolar plates (BPPs) using potentiostatic electrodeposition to improve their corrosion resistance and surface conductivity. A scanning electron microscope (SEM) was used to study the surface morphology of the prepared superhydrophobic films. The results show that the cobalt film modified by stearic acid (Co-SA) and cobalt–graphene composite modified by stearic acid (Co–G-SA) exhibit micro–nano structures. The results of the Fourier transforming infrared (FTIR) spectrophotometer confirm that the copper substrate was coated by Co-SA and Co–G-SA films. The wettability results of the prepared superhydrophobic films demonstrate that the films display superhydrophobicity, where the fabricated Co-SA and Co–G-SA films have contact angles (CAs) of 159 deg and 165 deg, respectively. Chemical stability, mechanical abrasion resistance, surface conductivity, and corrosion resistance in a simulated proton exchange membrane fuel cells (PEMFCs) environment are significantly higher for copper coated by Co–G-SA film. Because the copper coated with Co–G-SA has a low interfacial contact resistance (ICR) value and a high corrosion resistance, it is thought to be a good choice for PEMFC bipolar plates.

Long-term polarization accelerated degradation of nano-thin C/Ti coated SS316L bipolar plates used in polymer electrolyte membrane fuel cells

Dynamic potentials of polymer electrolyte membrane fuel cells (PEMFCs) lead to the corrosion of metal bipolar plates and significantly increase their interfacial contact resistance (ICR). Herein, two nano-thin C/Ti coatings with different thicknesses are prepared on SS316L (C/Ti/SS) and examined under three types of polarization potential modes. The C100Ti60 coating has improved corrosion resistance than C20Ti140 coating. The C100Ti60 coating exhibits a low ICR of 2.67 mΩ cm2 and a small corrosion rate of 1.47 μA/cm2, highlighting the high electrical conductivity and corrosion resistance. Moreover, C100Ti60/SS achieves a slight degradation of ICR after polarization at 0.67 V and cyclic polarization between 0.43 and 0.73 V. However, the high potential of 1.43 V induces severe delamination of C layer, resulting in a remarkable increase of ICR. Analysis suggests that the Ti layer improves the oxidation resistance and the C layer could provide effective protection when the potential is below 1.13 V.