Essential for compact and lightweight proton exchange membrane fuel cell (PEMFC) stacks, metallic bipolar plates (MBPs) suffer from durability and conductivity issues due to surface corrosion and passivation. This study conducts ex-situ characterization of Cr2SiC ceramic MAX phase coatings on stainless steel (SS) 316 L substrates to evaluate their suitability for MBP application. The investigation encompasses coating structure, surface morphology, corrosion resistance, surface wettability, in-plane electrical conductivity, and interfacial contact resistance. X-ray diffraction and X-ray photoelectron spectroscopy confirm the presence of Cr2SiC coatings on SS316L, while energy-dispersive X-ray spectroscopy verifies uniform coverage and elemental weight percentage. Corrosion resistance is evaluated using potentiostatic and potentiodynamic polarization tests, showing excellent resistance with low corrosion current density (Icorr) at both 25 °C (3.29E-03 μA/cm2) and 80 °C (4.32E-02 μA/cm2), meeting US Department of Energy (DOE) technical targets. Potentiodynamic polarization reveals large corrosion potential and small Icorr values at both temperatures, outperforming uncoated samples. Electrochemical impedance spectroscopy post-accelerated corrosion tests show high charge transfer resistance at 25 °C (3.68E+05 Ω cm2) and 80 °C (3.02E+05 Ω cm2), indicating stability in acidic environments. Surface wettability analysis indicates low water affinity with a large contact angle (75°) and low surface free energy (28.92 mJ/m2) for the coated samples as compared to the uncoated samples. Electrical conductivity meets DOE targets with an in-plane conductivity of 4.59E+05 S/m and interfacial contact resistance of 8.04 mΩcm2 after 5-h accelerated corrosion tests at 80 °C. These results suggest that Cr2SiC coated SS316L exhibits excellent corrosion resistance, surface wettability, and electrical characteristics, making them viable for PEMFC applications.
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