Fuel cell coatings

Advanced fuel cell coatings for an electrified world

Fuel cells (FC) generate electricity and heat from stored hydrogen and oxygen from the air, with water vapor as the only emission. Alongside batteries, fuel cells play an important role in electrifying our society. The two most common types of fuel cells are proton-exchange membrane (PEM) fuel cells, e.g. for mobility applications, and solid-oxide fuel cells (SOFC), primarily for stationary applications.

Protecting and enhancing the performance of fuel cells

Impact Coatings is a long-time provider of specialized coatings for PEM fuel cells, coatings that meet the industry’s requirements in terms of fuel cell functionality, long durability, and low cost. We also support the industry with coatings for SOFC and other fuel cell applications.

Metal bipolar (or monopolar) plates, as well as current collector plates and end plates, are core components in a PEM fuel cell stack – plates that need protection with a conductive and durable coating. Without coating, the plates will corrode and leak metal ions in the stack, which leads to reduced performance and in the end to failure of the fuel cell system.

A typical PEM fuel cell stack for automotive applications contains several hundred single fuel cells (“repeating unit”), where every repeating unit contains one bipolar plate (or two monopolar plates).

Fuel cells | Premium FC coating

Engineered for heavy-duty PEM fuel cell applications

To maintain the highest possible performance during the entire PEM fuel cell stack lifetime, a premium fuel cell coating needs to be able to withstand extreme potential spikes and temperatures without degradation. Such conditions can happen briefly during start-up and rapid load changes, which are part of normal usage for heavy-duty fuel cell applications. Over time, these short-lived yet very corrosive events become a serious problem if the metal plates in the stack cannot handle them.

With Impact Coatings’ robust, Premium FC coating, insignificant amounts of iron, chromium, and nickel are released at potentials up to 1.6 V vs. SHE (standard hydrogen electrode). In addition, excellent adhesion and conductivity, with stable and low interfacial contact resistance, are maintained throughout the stack’s lifetime.

Together with Impact Coatings’ INLINECOATER™ systems, the Premium FC coating is a perfect low-cost FC coating solution for PEM fuel cell metal plates for heavy-duty applications.

Key coating benefits

• Extreme corrosion resistance at 1.6 V
• Premium durability
• Excellent adhesion
• Low, stable interfacial contact resistance (ICR)

Technical overview

Fuel cells | Ceramic MAXPHASE™

Engineered for mid-end PEM fuel cell applications

The unique fuel cell coating Ceramic MAXPHASE™ is developed with cost-efficiency and reliability in mind as a protective and performance-enhancing coating for PEM fuel cell bipolar and monopolar plates in PEM fuel cell stacks. The Ceramic MAXPHASE™ coating provides low contact resistance and corrosion protection for high performance and increased durability.

Together with Impact Coatings’ INLINECOATER™ systems, Ceramic MAXPHASE™ is a perfect low-cost FC coating solution for PEM fuel cell metal plates for mid-end applications.

Key coating benefits

• Very low contact resistance
• High durability and performance
• Cost-efficient production
• Proven and reliable

Technical overview

Fuel cells | Noble metal coatings

For extreme performance PEM fuel cell applications

For extreme stack performance and lifespan, the metal bipolar plates in a PEM fuel cell stack can be coated with noble metals, gold, platinum, or for extreme performance, iridium. Although expensive, this guarantees excellent adhesion and conductivity with a stable and low interfacial contact resistance that will be maintained throughout the entire lifetime of the stack.

Key coating benefits

• Tailored thicknesses to customer requirements
• Excellent adhesion
• Basecoats possible
• Extreme performance

Technical overview