FUEL CELL COATINGS

Protecting and enhancing the performance of fuel cells

Impact Coatings is a long-time provider of coating solutions for fuel cells, coatings that meet the industry’s requirements in terms of fuel cell functionality, long durability, and low cost. We provide specialized coatings for proton-exchange membrane (PEM) fuel cells for various types of applications, with different requirements. We also provide coating solutions for interconnects in solid-oxide fuel cells (SOFC).

All Impact Coatings solutions are post-coatings, performed with PVD after forming of the plate components. This ensures the highest coating quality and guarantee that no cracks will form in the coatings.

PEM fuel cell coatings

Metal bipolar 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).

Premium FC Coating

Premium FC Coating

Product sheet

Ceramic MAXPHASE™

Ceramic MAXPHASE™

Product sheet


PEM 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

Technical overview

Applications
PEM fuel cells, heavy-duty applications
Monopolar and bipolar metal plates
Substrate material: Stainless steel 316L
Coating
MaterialCeramic
Thickness:0.1 µm
Color:Gray
PVD Process
Cycle time:Down to 36 seconds per batch
Performance
ICR on par with gold coating
Corrosion-resistant at 1.6 V vs. SHE
Passes US Department of Energy requirements
Product availability
Systems:IC2000, IC500
Coating services:Yes
Market introduction:2023

PEM 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

Technical overview

Applications
PEM fuel cells, mid-end applications
Monopolar and bipolar metal plates
Substrate material: Stainless steel 316L, titanium
Coating
Material:Ceramic
Thickness:0.1 µm
Color:Gray
PVD Process
Cycle time:Down to 36 seconds per batch
Performance
ICR on par with gold coating
Corrosion-resistant up to 0.8 V vs. SHE
Passes US Department of Energy requirements
Product availability
Systems:IC2000, IC500, IC500+
Coating services:Yes
Market introduction:2012

PEM 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

Technical overview

Applications
PEM fuel cells, extreme applications
Monopolar and bipolar metal plates
Substrate material: Stainless steel 316L, titanium
Coating
MaterialGold, platinum, iridium
Thickness:Customizable (1 nm and up)
PVD Process
Type:Plasma etching and sputtering
Cycle time:Depends on thickness, down to 36 s
Product availability
Systems:IC2000, IC500
Coating services:Yes