FUEL CELLS

Powering the electrified future

A fuel cell is an electrochemical cell that uses hydrogen chemical energy to produce electricity. When hydrogen acts as the energy carrier, the only products of the process are electricity, water, and heat.

Fuel cell systems can be dimensioned to produce energy for a wide range of applications in our society. It includes mobility applications, such as buses, trucks, cars, trains, forklifts and even airplanes, but also stationary applications for housing heat & power, infrastructure back-up power, and large power plants. Out of currently available technologies, proton-exchange membrane fuel cells (PEMFC, or PEM fuel cell) and solid-oxide fuel cells (SOFC) are at the forefront of development.

A single fuel cell consists of a set of components in a chemical electrolyte, which generates a small amount of power. To generate power for different needs, few up to hundreds of fuel cells are stacked, creating the core of a fuel cell system. Between every cell in the fuel cell stack are separator plates, also known as monopolar or bipolar plates, key components for the fuel cell system’s performance.

For increased stack performance and lifespan, metal bipolar plates in both PEMFC and SOFC stacks need protection with high-end, conductive, and corrosion resistant coatings. Uncoated metal plates corrode, and release metal ions into the stack. Such ions can irreversibly harm the fuel cell stack membrane’s functionality, further reducing power output. Overall, loss of conductivity and corrosion greatly reduces the lifetime of the fuel cell. This needs to be prevented. PEM fuel cells target lifetime according to the US Department of Energy is at least 30 000 hours for heavy duty applications and 8 000 hours for mid-end applications.

For PEM fuel cells in heavy duty mobility applications, to mitigate hydrogen starvation and maintain the highest possible performance during the entire stack lifetime, the coating should be able to withstand extreme potential spikes and temperatures without degradation.

Why PVD technology for fuel cells

• Corrosion Resistance: PVD coatings provide excellent protection against corrosion, which is crucial for the longevity and efficiency of fuel cells.
• Improved Conductivity: The coatings enhance the electrical conductivity of bipolar plates, which is essential for efficient energy transfer within the fuel cell.
• Durability: PVD coatings are highly durable and can withstand the harsh operating conditions of fuel cells, including high temperatures and chemical exposure.
• Cost-Effectiveness: PVD technology can reduce material costs by enabling less expensive base materials while achieving high performance.
• Environmental Benefits: PVD processes are generally more environmentally friendly compared to other coating methods, as they produce fewer hazardous by-products.