Corrosion behavior and surface structure analysis of pure aluminum immersed in fluoride‐sulfate solutions simulating polymer electrolyte membrane fuel cell‐produced water

Abstract Bipolar plates are the key component in polymer electrolyte membrane fuel cells (PEMFCs), which ensure the low cost of the fuel cell stack and furnish some of the important applications such as distributing the reactant gases, conducting the electrons, and removing the waste heat in PEMFCs. Thus, metallic bipolar plates (BPs), such as aluminum (Al), have attracted immense consideration and afford better performance in different machine‐driven applications and mass manufacturing opportunities. In order to increase the corrosion resistance of Al BPs, several methods are used and conducted by scientists. The corrosion behavior and surface structure analysis of pure Al were studied through the immersion process in fluoride‐sulfate solutions, assuming its use as BPs in PEMFC‐produced water. The open cell voltage, interfacial contact resistance, and polarization tests and the fuel cell operations were performed to evaluate cell voltage, current density, corrosion resistance, and the effect of fluoride and sulfate ions on the BPs in PEMFC. The hydrophobicity character of the surface of Al BPs was observed by the measurement of the wettability test. The atomic force microscopy images were taken to study the surface roughness, which was correlated with the corrosion rates of Al BPs. In addition, the amount of corrosion was calculated after 24–120 h of immersion in fluoride‐sulfate solutions. The scanning electron microscopy, transmission electron microscopy, and energy‐dispersive X‐ray spectroscopy data were analyzed to investigate the surface structure, morphology, and elemental analyses. Thus, the results found in this study revealed that Al‐based materials can be suitable for BPs in PEMFCs. Furthermore, it is noticed that the amount of corrosion was influenced by the presence of even a very small amount of fluoride ions present in the PEMFC environment, while it was suppressed efficiently by sulfate ions.