Corrosion-resistant lightweight metallic bipolar plates for PEM fuel cells

Corrosion resistant treated metal bipolar plates with higher rigidity and electrical conductivity than graphite were developed and tested for PEM fuel cell applications. Six replicas of single cells were used three of which were made of graphite composites bipolar plates and the other three of the treated metallic plates. A Membrane Electrode Assembly (MEA) with 5.55 cm2 active electrode areas, 0.3 mg cm−2 Pt loading and Nafion membrane 115 was fitted to each cell and operated under identical conditions. The experimental testing was conducted at room temperature (20 °C). The average value of the data obtained for the three graphite cells was plotted. Similarly, the average value of the data obtained for the three treated metal cells was plotted on the same graph for comparison. Generally, the treated metal bipolar plate provided at least 12% saving in hydrogen consumption in comparison to graphite. This is attributed to the lower bulk and surface contact resistance of the metal used in this study in relation to graphite. The results of lifetime testing, conducted at room temperature under variable loading showed no indication of power degradation due to metal corrosion for at least 1500 hours.