Aluminium is the Game-Changer for Hydrogen-Based Fuel Cells

I am happy to share our newest paper on materials for emerging hydrogen-based fuel cell technologies. I am particularly happy with this study as it is my first paper as a mentor!!! I have been mentoring Dr. Felipe Carneiro da Silva. He is a lecturer and a gifted scientist. He works at the São Paulo State Technological College (FATEC/SP) and he is an expert in thin film and coatings for emerging hydrogen-based technologies.

In this study, we are demonstrating the viability of using aluminium as a major material substrate for bipolar plates (BPPs) in proton exchange membrane fuel cells (PEMFCs). Given the urgent need for lightweight and cost-effective materials in the push towards vehicle electrification and reduced greenhouse gas emissions, aluminium is a promising candidate for BPPs in PEMFCs, replacing existing materials that are either expensive or subjected to export licensing.

But, the susceptibility of aluminium to corrosion in the harsh environments of PEMFCs has been a significant challenge. Our study showcases how high-performance titanium nitride (TiN) coatings can be synthesized and optimised to significantly enhance the corrosion resistance of aluminium, making it a practical choice for BPPs.

Our findings reveal that by carefully adjusting the synthesis settings during the grid-assisted magnetron sputtering process, we can produce TiN coatings with dense, defect-free microstructures that offer excellent protection to aluminium against corrosion. This breakthrough demonstrates that aluminium, when paired with our optimized TiN coatings, can effectively meet the demands of PEMFC applications (set by the U.S. Department of Energy). By making aluminum a usable substrate for BPPs, our research opens new avenues for cost-effective and sustainable fuel cell technologies in the automotive industry.