To convert chemical energy into electricity, fuel cells represent premier electrochemical devices. They consist of a membrane electrode assembly — comprising a catalyst-coated membrane and gas diffusion layers — and bipolar plates. These plates are critical components within the system. Their function is to manage water and heat removal, ensure uniform reactant gas distribution, and collect electrons generated by electrochemical reactions in the membrane electrode assembly. Despite significant recent progress in hydrogen production, storage, and utilization, technical challenges persist. In proton exchange membrane fuel cells (PEMFCs), replacing graphite bipolar plates (BPPs) with metallic alternatives offers substantial benefits due to their low density, high mechanical strength, negligible hydrogen permeability, and cost-effectiveness. Stainless steel (SS) and titanium stand out as competitive candidates for BPPs among diverse metals because they combine excellent mechanical performance with economic efficiency. However, to protect metallic BPPs against corrosion and passivation in the acidic, warm, and humid PEMFC environment, advanced coatings and surface modifications remain essential. This study aims to develop innovative protective coatings using physical vapor deposition techniques to protect stainless steel and titanium substrates against electrochemical corrosion under PEMFC operating conditions. The chemical and morphological characteristics of the sample were analyzed by XRD analysis and SEM microscopy coupled with EDS macroanalysis. The performance of the coatings was investigated through contact resistance measurements and corrosion resistance tests. The latter were conducted in an acidic environment (0.05〖" M H" 〗_2 〖"SO" 〗_4+0.1〖" ppm F" 〗^-) at 70 °C to simulate PEM. Despite the low thickness of the coating, good corrosion resistance was demonstrated for both titanium and stainless steel substrates.
RF Magnetron Sputtered Nanometric Pd-Ag Coatings for Corrosion Protection of Titanium and Stainless Steel Bipolar Plates in PEM Fuel Cells / Gulino, M., Zola, D., Zagoraiou, E., Serra, E., Feroci, M., Maria Moschovi, A., Yakoumis, I., Luisa Grilli, M.. - (2026). (Nanoinnovation 2026 Roma ).
RF Magnetron Sputtered Nanometric Pd-Ag Coatings for Corrosion Protection of Titanium and Stainless Steel Bipolar Plates in PEM Fuel Cells
Miryam Gulino
;Marta Feroci;
2026
Abstract
To convert chemical energy into electricity, fuel cells represent premier electrochemical devices. They consist of a membrane electrode assembly — comprising a catalyst-coated membrane and gas diffusion layers — and bipolar plates. These plates are critical components within the system. Their function is to manage water and heat removal, ensure uniform reactant gas distribution, and collect electrons generated by electrochemical reactions in the membrane electrode assembly. Despite significant recent progress in hydrogen production, storage, and utilization, technical challenges persist. In proton exchange membrane fuel cells (PEMFCs), replacing graphite bipolar plates (BPPs) with metallic alternatives offers substantial benefits due to their low density, high mechanical strength, negligible hydrogen permeability, and cost-effectiveness. Stainless steel (SS) and titanium stand out as competitive candidates for BPPs among diverse metals because they combine excellent mechanical performance with economic efficiency. However, to protect metallic BPPs against corrosion and passivation in the acidic, warm, and humid PEMFC environment, advanced coatings and surface modifications remain essential. This study aims to develop innovative protective coatings using physical vapor deposition techniques to protect stainless steel and titanium substrates against electrochemical corrosion under PEMFC operating conditions. The chemical and morphological characteristics of the sample were analyzed by XRD analysis and SEM microscopy coupled with EDS macroanalysis. The performance of the coatings was investigated through contact resistance measurements and corrosion resistance tests. The latter were conducted in an acidic environment (0.05〖" M H" 〗_2 〖"SO" 〗_4+0.1〖" ppm F" 〗^-) at 70 °C to simulate PEM. Despite the low thickness of the coating, good corrosion resistance was demonstrated for both titanium and stainless steel substrates.I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
