Overcoming the Dilemma between Low Electrical Resistance and High Corrosion Resistance Using a Ta/(Ta,Ti)N/TiN/Ti Multilayer for Proton Exchange Membrane Fuel Cells

Bipolar plates in proton exchange membrane fuel cells (PEMFCs) are confronted by the dilemma of low contact resistance and high corrosion resistance; this study aimed to simultaneously satisfy these dimensions in a harsh environment. Using thick multilayer coatings can improve the corrosion resistance, but the contact resistance would be largely compromised. To address this challenge, we propose compatible tantalum/titanium-based coatings on 316L stainless steel (SS316L) as bipolar plates for PEMFCs. With the transition layer, the optimal TaN/(Ta,Ti)N/TiN/Ti coating exhibits an ultralow corrosion current density of 0.369 μA·cm−2 (at +0.6 V vs. SCE) and a contact resistance of 6 mΩ cm2 at 138 N/cm2 after 5 h of potentiostatic polarization, both of which meet the standard of the U.S. Department of Energy. Electrochemical impedance spectroscopy (EIS) and an equivalent electrical circuit model further elucidated that TaN/(Ta,Ti)N/TiN/Ti coating significantly impedes the oxidation reaction and dissolution of metals and provides good protection for the SS316L.