Accelerated corrosion and electrochemical characteristics of carbon-coated titanium bipolar plates by doctor-blade technology for PEMFC

In this investigation, a carbon layer was coated onto a TiO 2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of titanium bipolar plates for PEMFCs. XRD analysis confirmed the formation of anatase-phase TiO₂. And cross-sectional SEM–EDS analysis verified t...

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Published inNpj Materials degradation Vol. 9; no. 1; pp. 105 - 16
Main Authors Hwang, Hyun-Kyu, Kim, Seong-Jong
Format Journal Article
LanguageEnglish
Published London Nature Publishing Group UK 13.08.2025
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ISSN2397-2106
2397-2106
DOI10.1038/s41529-025-00651-1

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Abstract In this investigation, a carbon layer was coated onto a TiO 2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of titanium bipolar plates for PEMFCs. XRD analysis confirmed the formation of anatase-phase TiO₂. And cross-sectional SEM–EDS analysis verified the presence of the carbon layer. In ex-situ accelerated corrosion experiments simulating PEMFC environments, Ti with TiO 2 +carbon coatings presented higher current density than bare Ti. This is interpreted as being due to the capacitive charge/discharge behavior of the electric double layer formed by the carbon layer. But, the coated specimen met the U.S. DOE corrosion resistance criterion (i corr  < 1 μA/cm 2 ). Especially, bare Ti failed to meet the interfacial contact resistance (ICR) standard both before and after testing. In contrast, the TiO₂+carbon-coated specimen maintained ICR values below 10 mΩ·cm 2 at 140 N/cm 2 . In addition, SEM analysis after all electrochemical experiments confirmed that the coating remained free of delamination or damage. In particular, cyclic voltammetry experiment results further confirmed stable capacitive behavior even after 300 cycles. These findings indicate that doctor blade-based TiO 2 +carbon coatings are effective in enhancing both corrosion resistance and electrical conductivity. This suggests that the proposed process is a viable alternative to conventional PVD or CVD methods for commercialization.
AbstractList In this investigation, a carbon layer was coated onto a TiO2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of titanium bipolar plates for PEMFCs. XRD analysis confirmed the formation of anatase-phase TiO₂. And cross-sectional SEM–EDS analysis verified the presence of the carbon layer. In ex-situ accelerated corrosion experiments simulating PEMFC environments, Ti with TiO2+carbon coatings presented higher current density than bare Ti. This is interpreted as being due to the capacitive charge/discharge behavior of the electric double layer formed by the carbon layer. But, the coated specimen met the U.S. DOE corrosion resistance criterion (icorr < 1 μA/cm2). Especially, bare Ti failed to meet the interfacial contact resistance (ICR) standard both before and after testing. In contrast, the TiO₂+carbon-coated specimen maintained ICR values below 10 mΩ·cm2 at 140 N/cm2. In addition, SEM analysis after all electrochemical experiments confirmed that the coating remained free of delamination or damage. In particular, cyclic voltammetry experiment results further confirmed stable capacitive behavior even after 300 cycles. These findings indicate that doctor blade-based TiO2+carbon coatings are effective in enhancing both corrosion resistance and electrical conductivity. This suggests that the proposed process is a viable alternative to conventional PVD or CVD methods for commercialization.
In this investigation, a carbon layer was coated onto a TiO 2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of titanium bipolar plates for PEMFCs. XRD analysis confirmed the formation of anatase-phase TiO₂. And cross-sectional SEM–EDS analysis verified the presence of the carbon layer. In ex-situ accelerated corrosion experiments simulating PEMFC environments, Ti with TiO 2 +carbon coatings presented higher current density than bare Ti. This is interpreted as being due to the capacitive charge/discharge behavior of the electric double layer formed by the carbon layer. But, the coated specimen met the U.S. DOE corrosion resistance criterion (i corr  < 1 μA/cm 2 ). Especially, bare Ti failed to meet the interfacial contact resistance (ICR) standard both before and after testing. In contrast, the TiO₂+carbon-coated specimen maintained ICR values below 10 mΩ·cm 2 at 140 N/cm 2 . In addition, SEM analysis after all electrochemical experiments confirmed that the coating remained free of delamination or damage. In particular, cyclic voltammetry experiment results further confirmed stable capacitive behavior even after 300 cycles. These findings indicate that doctor blade-based TiO 2 +carbon coatings are effective in enhancing both corrosion resistance and electrical conductivity. This suggests that the proposed process is a viable alternative to conventional PVD or CVD methods for commercialization.
Abstract In this investigation, a carbon layer was coated onto a TiO2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of titanium bipolar plates for PEMFCs. XRD analysis confirmed the formation of anatase-phase TiO₂. And cross-sectional SEM–EDS analysis verified the presence of the carbon layer. In ex-situ accelerated corrosion experiments simulating PEMFC environments, Ti with TiO2+carbon coatings presented higher current density than bare Ti. This is interpreted as being due to the capacitive charge/discharge behavior of the electric double layer formed by the carbon layer. But, the coated specimen met the U.S. DOE corrosion resistance criterion (icorr < 1 μA/cm2). Especially, bare Ti failed to meet the interfacial contact resistance (ICR) standard both before and after testing. In contrast, the TiO₂+carbon-coated specimen maintained ICR values below 10 mΩ·cm2 at 140 N/cm2. In addition, SEM analysis after all electrochemical experiments confirmed that the coating remained free of delamination or damage. In particular, cyclic voltammetry experiment results further confirmed stable capacitive behavior even after 300 cycles. These findings indicate that doctor blade-based TiO2+carbon coatings are effective in enhancing both corrosion resistance and electrical conductivity. This suggests that the proposed process is a viable alternative to conventional PVD or CVD methods for commercialization.
ArticleNumber 105
Author Kim, Seong-Jong
Hwang, Hyun-Kyu
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Snippet In this investigation, a carbon layer was coated onto a TiO 2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of...
In this investigation, a carbon layer was coated onto a TiO2 surface using a roll-to-roll doctor blade method to enhance the electrochemical performance of...
Abstract In this investigation, a carbon layer was coated onto a TiO2 surface using a roll-to-roll doctor blade method to enhance the electrochemical...
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SubjectTerms 639/166
639/301
Anatase
Carbon
Chemical vapor deposition
Chemistry and Materials Science
Coatings
Commercialization
Contact resistance
Corrosion and Coatings
Corrosion resistance
Electric contacts
Electric double layer
Electrical resistivity
Electrochemical analysis
Electrochemistry
Fuel cells
Graphene
Interfaces
Manufacturers
Materials Science
Nanocrystals
Plates
Spectrum analysis
Stainless steel
Structural Materials
Titanium
Titanium dioxide
Tribology
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Title Accelerated corrosion and electrochemical characteristics of carbon-coated titanium bipolar plates by doctor-blade technology for PEMFC
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