Comparative review of corrosion-resistant coatings on metal bipolar plates of proton exchange membrane fuel cells

In the realm of proton exchange membrane fuel cells(PEMFCs),the bipolar plates(BPs)are indispensable and serve pivotal roles in distributing reactant gases,collecting current,facilitating product water removal,and cooling the stack.Metal BPs,characterized by outstanding manufacturability,cost-effectiveness,higher power density,and mechanical strength,are emerging as viable alternatives to traditional graphite BPs.The foremost challenge for metal BPs lies in enhancing their corrosion resistance and conductivity under acidic conditions,necessitating the application of various coatings on their surfaces to ensure superior performance.This review summarizes and compares recent advancements in the research of eight distinct types of coatings for BPs in PEMFCs,including noble metal,carbide,ni-tride,and amorphous carbon(a-C)/metal compound composite coatings.The various challenges encountered in the manufacturing and fu-ture application of these coatings are also delineated.

Effects of baffle position in serpentine flow channel on the performance of proton exchange membrane fuel cells

This study used a three-dimensional numerical model of a proton exchange membrane fuel cell with five types of channels:a smooth channel(Case 1);eight rectangular baffles were arranged in the upstream(Case 2),midstream(Case 3),downstream(Case 4),and the entire cathode flow channel(Case 5)to study the effects of baffle position on mass transport,power density,net power,etc.Moreover,the effects of back pressure and humidity on the voltage were investigated.Results showed that compared to smooth channels,the oxygen and water transport facilitation at the diffusion layer-channel interface were added 11.53%-20.60%and 7.81%-9.80%at 1.68 A·cm^(-2)by adding baffles.The closer the baffles were to upstream,the higher the total oxygen flux,but the lower the flux uniformity the worse the water removal.The oxygen flux of upstream baffles was 8.14%higher than that of downstream baffles,but oxygen flux uniformity decreased by 18.96%at 1.68 A·cm^(-2).The order of water removal and voltage improvement was Case 4>Case 5>Case 3>Case 2>Case 1.Net power of Case 4 was 9.87%higher than that of the smooth channel.To the Case 4,when the cell worked under low back pressure or high humidity,the voltage increments were higher.The potential increment for the back pressure of 0 atm was 0.9%higher than that of 2 atm(1 atm=101.325 kPa).The potential increment for the humidity of 100%was 7.89%higher than that of 50%.

CFD Analysis of Spiral Flow Fields in Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells(PEMFCs)are largely used in various applications because of their pollution-free products and high energy conversion efficiency.In order to improve the related design,in the present work a new spiral flow field with a bypass is proposed.The reaction gas enters the flow field in the central path and diffuses in two directions through the flow channel and the bypass.The bypasses are arranged incrementally.The number of bypasses and the cross-section size of the bypasses are varied parametrically while a single-cell model of the PEMFC is used.The influence of the concentration of liquid water and oxygen in the cell on the performance of different flow fields is determined by means of Computational fluid dynamics(COMSOL Multiphysics software).Results show that when the bypass number is 48 and its cross-sectional area is 0.5 mm^(2),the cell exhibits the best performances.

Pore-Scale Investigation of Coupled Two-Phase and Reactive Transport in the Cathode Electrode of Proton Exchange Membrane Fuel Cells

A three-dimensional multicomponent multiphase lattice Boltzmann model(LBM)is established to model the coupled two-phase and reactive transport phenomena in the cathode electrode of proton exchange membrane fuel cells.The gas diff usion layer(GDL)and microporous layer(MPL)are stochastically reconstructed with the inside dynamic distribution of oxygen and liquid water resolved,and the catalyst layer is simplifi ed as a superthin layer to address the electrochemical reaction,which provides a clear description of the fl ooding eff ect on mass transport and performance.Diff erent kinds of electrodes are reconstructed to determine the optimum porosity and structure design of the GDL and MPL by comparing the transport resistance and per-formance under the fl ooding condition.The simulation results show that gradient porosity GDL helps to increase the reactive area and average concentration under fl ooding.The presence of the MPL ensures the oxygen transport space and reaction area because liquid water cannot transport through micropores.Moreover,the MPL helps in the uniform distribution of oxygen for an effi cient in-plane transport capacity.Crack and perforation structures can accelerate the water transport in the assembly.The systematic perforation design yields the best performance under fl ooding by separating the transport of liquid water and oxygen.

Carbon-supported ultrafine Pt nanoparticles modified with trace amounts of cobalt as enhanced oxygen reduction reaction catalysts for proton exchange membrane fuel cells

To accelerate the kinetics of the oxygen reduction reaction(ORR)in proton exchange membrane fuel cells,ultrafine Pt nanoparticles modified with trace amounts of cobalt were fabricated and decorated on carbon black through a strategy involving modified glycol reduction and chemical etching.The obtained Pt36Co/C catalyst exhibits a much larger electrochemical surface area(ECSA)and an improved ORR electrocatalytic activity compared to commercial Pt/C.Moreover,an electrode prepared with Pt36Co/C was further evaluated under H2-air single cell test conditions,and exhibited a maximum specific power density of 10.27 W mgPt^-1,which is 1.61 times higher than that of a conventional Pt/C electrode and also competitive with most state-of-the-art Pt-based architectures.In addition,the changes in ECSA,power density,and reacting resistance during the accelerated degradation process further demonstrate the enhanced durability of the Pt36Co/C electrode.The superior performance observed in this work can be attributed to the synergy between the ultrasmall size and homogeneous distribution of catalyst nanoparticles,bimetallic ligand and electronic effects,and the dissolution of unstable Co with the rearrangement of surface structure brought about by acid etching.Furthermore,the accessible raw materials and simplified operating procedures involved in the fabrication process would result in great cost-effectiveness for practical applications of PEMFCs.

Graphite-polypyrrole coated 316L stainless steel as bipolar plates for proton exchange membrane fuel cells

316L stainless steel（SS 316L） is quite attractive as bipolar plates in proton exchange membrane fuel cells（PEMFC）.In this study,graphite-polypyrrole was coated on SS 316L by the method of cyclic voltammetry.The surface morphology and chemical composition of the graphite-polypyrrole composite coating were investigated by scanning electron microscopy（SEM） and X-ray photoelectron spectroscopy（XPS）.A simulated working environment of PEMFC was applied for testing the corrosion properties of graphite-polypyrrole coated SS 316L.The current densities in the simulated PEMFC anode and cathode conditions are around 3×10-9 and 9×10-5 A·cm-2,respectively.In addition,the interfacial contact resistance（ICR） was also investigated.The ICR value of graphite-polypyrrole coated SS 316L is much lower than that of bare SS 316L.Therefore,graphite-polypyrrole coated SS 316L indicates a great potential for the application in PEMFC.

Pt/WO_3/C nanocomposite with parallel WO_3 nanorods as cathode catalyst for proton exchange membrane fuel cells

Pt/WO3/C nanocomposites with parallel WO3 nanorods were synthesized and applied as the cathode catalyst for proton exchange membrane fuel cells （PEMFCs）. Electrochemical results and single cell tests show that an enhanced activity for the oxygen reduction reaction （ORR） is obtained for the Pt/WO3/C catalyst compared with Pt/C. The higher catalytic activity might be ascribed to the improved Pt dispersion with smaller particle sizes. The Pt/WO3/C catalyst also exhibits a good electrochemical stability under potential cycling. Thus, the Pt/WO3/C catalyst can be used as a potential PEMFC cathode catalyst.

Recent advances in phosphoric acid-based membranes for high-temperature proton exchange membrane fuel cells

High-temperature proton exchange membrane fuel cells(HT-PEMFCs)are pursued worldwide as efficient energy conversion devices.Great efforts have been made in the area of designing and developing phosphoric acid(PA)-based proton exchange membrane(PEM)of HT-PEMFCs.This review focuses on recent advances in the limitations of acid-based PEM(acid leaching,oxidative degradation,and mechanical degradation)and the approaches mitigating the membrane degradation.Preparing multilayer or polymers with continuous network,adding hygroscopic inorganic materials,and introducing PA doping sites or covalent interactions with PA can effectively reduce acid leaching.Membrane oxidative degradation can be alleviated by synthesizing crosslinked or branched polymers,and introducing antioxidative groups or highly oxidative stable materials.Crosslinking to get a compact structure,blending with stable polymers and inorganic materials,preparing polymer with high molecular weight,and fabricating the polymer with PA doping sites away from backbones,are recommended to improve the membrane mechanical strength.Also,by comparing the running hours and decay rate,three current approaches,1.crosslinking via thermally curing or polymeric crosslinker,2.incorporating hygroscopic inorganic materials,3.increasing membrane layers or introducing strong basic groups and electron-withdrawing groups,have been concluded to be promising approaches to improve the durability of HT-PEMFCs.The overall aim of this review is to explore the existing degradation challenges and opportunities to serve as a solid basis for the deployment in the fuel cell market.

Patterned catalyst layer boosts the performance of proton exchange membrane fuel cells by optimizing water management

Mass transport is crucial to the performance of proton exchange membrane fuel cells,especially at high current densities.Generally,the oxygen and the generated water share same transmission medium but move towards opposite direction,which leads to serious mass transfer problems.Herein,a series of patterned catalyst layer were prepared with a simple one-step impressing method using nylon sieves as templates.With grooves 100μm in width and 8μm in depth on the surface of cathode catalyst layer,the maximum power density of fuel cell increases by 10%without any additional durability loss while maintaining a similar electrochemical surface area.The concentration contours calculated by finite element analysis reveal that the grooves built on the surface of catalyst layer serve to accumulate the water nearby while oxygen tends to transfer through relatively convex region,which results from capillary pressure difference caused by the pore structure difference between the two regions.The separation of oxidant gas and generated water avoids mass confliction thus boosts mass transport efficiency.

In situ grown nanoscale platinum on carbon powder as catalyst layer in proton exchange membrane fuel cells(PEMFCs)

An extensive study has been conducted on the proton exchange membrane fuel cells （PEMFCs） with reducing Pt loading. This is commonly achieved by developing methods to increase the utilization of the platinum in the catalyst layer of the electrodes. In this paper, a novel process of the catalyst layers was introduced and investigated. A mixture of carbon powder and Nafion solution was sprayed on the glassy carbon electrode （GCE） to form a thin carbon layer. Then Pt particles were deposited on the surface by reducing hexachloroplatinic （IV） acid hexahydrate with methanoic acid. SEM images showed a continuous Pt gradient profile among the thickness direction of the catalytic layer by the novel method. The Pt nanowires grown are in the size of 3 nm （diameter） x l0 nm （length） by high solution TEM image. The novel catalyst layer was characterized by cyclic voltammetry （CV） and scanning electron microscope （SEM） as compared with commercial Pt/C black and Pt catalyst layer obtained from sputtering. The results showed that the platinum nanoparticles deposited on the carbon powder were highly utilized as they directly faced the gas diffusion layer and offered easy access to reactants （oxygen or hydrogen）.

Water Distribution and Removal along the Flow Channel in Proton Exchange Membrane Fuel Cells

Distribution expressions of total gas pressure and partial water vapor pressure along the channel direction were established based on lumped model by analyzing pressure loss in the channel and gas diffusion in the layer. The mechanism of droplet formation in the flow channel was also analyzed. Effects of the relative humidity, working temperature and stoichiometry on liquid water formation were discussed in detail. Moreover, the force equilibrium equation of the droplet in the flow channel was deduced, and the critical flow velocity for the water droplet removal was also addressed. The experimental results show that the threshold position of the liquid droplet is far from the inlet with the increase of temperature, and it decreases with the increase of the inlet total pressure. The critical flow velocity decreases with the increase of the radius and the working pressure.

Multiscale structural engineering of atomically dispersed FeN4 electrocatalyst for proton exchange membrane fuel cells

Atomically dispersed iron-nitrogen-carbon(Fe-N-C) catalysts have emerged as the most promising alternative to the expensive Pt-based catalysts for the oxygen reduction reaction(ORR) in proton exchange membrane fuel cells(PEMFCs),however suffer from low site density of active Fe-N4 moiety and limited mass transport during the catalytic reaction.To address these challenges,we report a three-dimensional(3D) metal-organic frameworks(MOF)-derived Fe-N-C single-atom catalyst.In this well-designed Fe-N-C catalyst,the micro-scale interconnected skeleton,the nano-scale ordered pores and the atomic-scale abundant carbon edge defects inside the skeleton significantly enhance the site density of active Fe-N4 moiety,thus improving the Fe utilization in the final catalyst.Moreover,the combination of the above mentioned micro-and nano-scale structures greatly facilitates the mass transport in the 3D Fe-N-C catalyst.Therefore,the multiscale engineered Fe-N-C single-atom catalyst achieves excellent ORR performance under acidic condition and affords a significantly enhanced current density and power density in PEMFC.Our findings may open new opportunities for the rational design of FeN-C catalysts through multiscale structural engineering.

Ti/(Ti,Cr)N/CrN multilayer coated 316L stainless steel by arc ion plating as bipolar plates for proton exchange membrane fuel cells

Arc ion plating (AIP) is applied to form Ti/(Ti,Cr)N/CrN multilayer coating on the surface of 316L stainless steel (SS316L) as bipolar plates for proton exchange membrane fuel cells (PEMFCs). The characterizations of the coating are analyzed by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Interfacial contact resistance (ICR) between the coated sample and carbon paper is 4.9 m Omega cm(2) under 150 N/cm(2), which is much lower than that of the SS316L substrate. Potentiodynamic and potentiostatic tests are performed in the simulated PEMFC working conditions to investigate the corrosion behaviors of the coated sample. Superior anticorrosion performance is observed for the coated sample, whose corrosion current density is 0.12 mu A/cm(2). Surface morphology results after corrosion tests indicate that the substrate is well protected by the multilayer coating. Performances of the single cell with the multilayer coated SS316L bipolar plate are improved significantly compared with that of the cell with the uncoated SS316L bipolar plate, presenting a great potential for PEMFC application. (C) 2016 Science Press and Dalian Institute of Chemical Physics, Chinese Academy of Sciences. Published by Elsevier B.V. and Science Press. All rights reserved.

Process and challenges of stainless steel based bipolar plates for proton exchange membrane fuel cells

Proton exchange membrane fuel cell(PEMFC)powered automobiles have been recognized to be the ultimate solution to replace traditional fuel automobiles because of their advantages of PEMFCs such as no pollution,low temperature start-up,high energy density,and low noise.As one of the core components,the bipolar plates(BPs)play an important role in the PEMFC stack.Traditional graphite BPs and composite BPs have been criticized for their shortcomings such as low strength,high brittleness,and high processing cost.In contrast,stainless steel BPs(SSBPs)have recently attracted much attention of domestic and foreign researchers because of their excellent comprehensive performance,low cost,and diverse options for automobile applications.However,the SSBPs are prone to corrosion and passivation in the PEMFC working environment,which lead to reduced output power or premature failure.This review is aimed to summarize the corrosion and passivation mechanisms,characterizations and evaluation,and the surface modification technologies in the current SSBPs research.The non-coating and coating technical routes of SSBPs are demonstrated,such as substrate component regulation,thermal nitriding,electroplating,ion plating,chemical vapor deposition,and physical vapor deposition,etc.Alternative coating materials for SSBPs are metal coatings,metal nitride coatings,conductive polymer coatings,and polymer/carbon coatings,etc.Both the surface modification technologies can solve the corrosion resistance problem of stainless steel without affecting the contact resistance,however still facing restraints such as long-time stability,feasibility of low-cost,and mass production process.This paper is believed to enrich the knowledge of high-performance and long-life BPs applied for PEMFC automobiles.

Design and Performance Analysis of Micro Proton Exchange Membrane Fuel Cells

This study describes a novel micro proton exchange membrane fuel cell(PEMFC)(active area,2.5 cm2).The flow field plate is manufactured by applying micro-electromechanical systems(MEMS) technology to silicon substrates to etch flow channels without a gold-coating.Therefore,this investigation used MEMS technology for fabrication of a flow field plate and presents a novel fabrication procedure.Various operating parameters,such as fuel temperature and fuel stoichiometric flow rate,are tested to optimize micro PEMFC performance.A single micro PEMFC using MEMS technology reveals the ideal performance of the proposed fuel cell.The optimal power density approaches 232.75 mW·cm-1 when the fuel cell is operated at ambient condition with humidified,heated fuel.

Highly active and durable core-shell electrocatalysts for proton exchange membrane fuel cells

This work presents simple post-treatment methods to selectively and partially remove the Pd core of Pd-Pt core–shell(Pt@Pd/C)catalysts.The proton exchange membrane fuel cell with the post-treated Pt@Pd/C cathode(Pt loading:0.10 mg·cm^(-2))delivers an impressive peak power density of 1.2 W·cm^(-2).The partial removal of Pd core endows an ultrahigh oxygen reduction reaction(ORR)mass activity of 0.32 A·g_(PGM)-1 when normalized to the platinum group metal(PGM)mass,or equivalently 0.55 A·mg_(Pt)^(-1) at 0.9 V measured in a fuel cell.The post-treatment thickens the Pt shells and mitigates the Pd dissolution during potential cycling.As a result,the post-treated core-shell catalyst demonstrates superior durability in ORR mass activity and polarization power density retention than untreated core-shell catalyst and benchmark Pt/C.In-situ inductively coupled plasmamass spectrometry(ICP-MS)results highlight that the amount of dissolved Pd in post-treated core–shell catalyst is 17-times lower than that of the untreated one.Our findings highlight the importance of structural tuning of catalysts in enhancing their mass activity and durability.

A machine learning driven 3D+1D model for efficient characterization of proton exchange membrane fuel cells

The computational demands of 3D continuum models for proton exchange membrane fuel cells remain substantial. One prevalent approach is the hierarchical model combining a 2D/3D flow field with a 1D sub-model for the catalyst layers and membrane. However, existing studies often simplify the 1D domain to a linearized 0D lumped model, potentially resulting in significant errors at high loads. In this study, we present a computationally efficient neural network driven 3D+1D model for proton exchange membrane fuel cells. The 3D sub-model captures transport in the gas channels and gas diffusion layers and is coupled with a 1D electrochemical sub-model for microporous layers, membrane, and catalyst layers. To reduce computational intensity of the full 1D description, a neural network surrogates the 1D electrochemical sub-model for coupling with the 3D domain. Trained by model-generated large synthetic datasets, the neural network achieves root mean square errors of less than 0.2%. The model is validated against experimental results under various relative humidities. It is then employed to investigate the nonlinear distribution of internal states under different operating conditions. With the neural network operating at 0.5% of the computing cost of the 1D sub-model, the hybrid model preserves a detailed and nonlinear representation of the internal fuel cell states while maintaining computational costs comparable to conventional 3D+0D models. The presented hybrid data-driven and physical modeling framework offers high accuracy and computing speed across a broad spectrum of operating conditions, potentially aiding the rapid optimization of both the membrane electrode assembly and the gas channel geometry.

Recent development in degradation mechanisms of proton exchange membrane fuel cells for vehicle applications:problems,progress,and perspectives

Due to its zero emissions,high efficiency and low noise,proton exchange membrane fuel cell(PEMFC)is full of potential for the application of vehicle power source.Nonetheless,its lifespan and durability remain multiple obstacles to be solved before widespread commercialization.Frequent exposure to non-rated operating conditions could considerably accelerate the degradation of the PEMFC in various forms,thus reducing its durability.This paper first analyzes degradation mechanisms of PEMFCs under typical automotive operating conditions,including idling,startup-shutdown,dynamic loads,and cold start.The corresponding accelerated stress testing methods are also discussed.Then,as the impurities existed in the reaction gas source and generated from the degradation of the PEMFC itself may occur under all automotive conditions,the degradation mechanisms caused by impurity contamination are classified and reviewed in detail.After that,the techniques proposed by researchers to enhance the durability of PEMFCs are presented from four aspects:membrane electrode assembly materials,bipolar plates and flow fields design,stack assembly,and cell control strategies.The challenges in the field and the prospects for the future are summarized and analyzed at the end.The aim of this work is to provide guidelines for improving the durability of PEMFCs in vehicle applications.

Secondary reduction strategy synthesis of Pt-Co nanoparticle catalysts towards boosting the activity of proton exchange membrane fuel cells

Based on the volcanic relationship between catalytic activity and key adsorption energies,Pt-Co alloy materials have been widely studied as cathode oxygen reduction reaction(ORR)catalysts in proton exchange membrane fuel cells(PEMFCs)due to their higher active surface area and adjustable D-band energy levels compared to Pt/C.However,how to balance the alloying degree and ORR performance of Pt-Co catalyst remains a great challenge.Herein,we first synthesized a well-dispersed Pt/Co/C precursor by using a mild dimethylamine borane(DMAB)as the reducing agent.The precursor was calcined at high temperature under H_(2)/Ar mixed gas by a secondary reduction strategy to obtain an ordered Pt_(3)Co intermetallic compound nanoparticle catalyst with a high degree of alloying.The optimization of elec-tronic structure due to Pt-Co alloying and the strong metal-carrier interaction ensure the high kinetic activity of the cell membrane electrode.Additionally,the high degree of graphitization increases the electrical conductivity during the reaction.As a result,the activity and stability of the catalyst were significantly improved,with a half-wave potential as high as 0.87 V,which decreased by only 20 mV after 10000 potential cycles.Single-cell tests further validate the high intrinsic activity of the ordered Pt_(3)Co catalyst with mass activity up to 0.67 A mg_(pt)^(-1),exceeding the United States Department of Energy(US DOE)standard(0.44 A mg_(pt)^(-1)),and a rated power of 5.93 W mg_(pt)^(-1).

Overcoming the Electrode Challenges of High‑Temperature Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells(PEMFCs)are becoming a major part of a greener and more sustainable future.However,the costs of high-purity hydrogen and noble metal catalysts alongside the complexity of the PEMFC system severely hamper their commercialization.Operating PEMFCs at high temperatures(HT-PEMFCs,above 120℃)brings several advantages,such as increased tolerance to contaminants,more affordable catalysts,and operations without liquid water,hence considerably simplifying the system.While recent progresses in proton exchange mem-branes for HT-PEMFCs have made this technology more viable,the HT-PEMFC viscous acid electrolyte lowers the active site utilization by unevenly diffusing into the catalyst layer while it acutely poisons the catalytic sites.In recent years,the synthesis of platinum group metal(PGM)and PGM-free catalysts with higher acid tolerance and phosphate-promoted oxygen reduction reaction,in conjunction with the design of catalyst layers with improved acid distribution and more triple-phase boundaries,has provided great opportunities for more efficient HT-PEMFCs.The progress in these two interconnected fields is reviewed here,with recommendations for the most promising routes worthy of further investigation.Using these approaches,the performance and durability of HT-PEMFCs will be significantly improved.