Surface Engineering of Bipolar Plates for PEM-Water Electrolysis : Cost-Effective Corrosion Protection

Hydrogen production by PEM-Water electrolysis is an environmentally benign and promising approach to store excess energy from renewable energy sources but facing drawbacks of high costs, mainly due to a harsh cell-environment. The aim of my Master Thesis was to reduce the costs of the most expensive cell component, the bipolar plate by surface engineering. Thin films of Ti, Zr and alloys thereof, as well as Nb and W have been vapor deposited by either cathodic arc deposition or magnetron sputtering in an industrial scale coating system. The nitrides, carbides, and pure metals from the previously mentioned transition metals were investigated by crosscut adhesion tests, interfacial contact resistance, electrochemical corrosion tests, scanning electron microscopy and energy dispersive X-ray spectroscopy. Highly promising thin film materials have been developed to functionalize the bipolar plates, enabling significant cost reductions of the PEMWE-cell