Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material Preparation
2.2. Deposition of Coating
2.3. Coating Characterization
3. Results and Discussion
3.1. Coating Structure
3.2. Characterization of Mechanical Properties
3.3. Electrochemical Corrosion Behavior Test
3.4. ICR Test
4. Conclusions
- The embedded graphite-like particles effectively reduced the longitudinal resistance of the coatings. Under pressure, these particles increased the contact area between the coating and the GDL, significantly reducing the ICR. However, during corrosion, tiny gaps between the particles and the coating served as pathways for corrosive ions, reducing the coating’s corrosion resistance. Additionally, the corrosion potential difference between the particles and the coating led to galvanic effects, with the graphite-like particles being preferentially corroded due to their lower corrosion potential. The samples prepared using FCVA technology, which lacked embedded carbon particles, demonstrated excellent corrosion resistance under various conditions but exhibited higher contact resistance due to the absence of graphite-like particles.
- The sp2-hybridized carbon structures within the a-C coatings were susceptible to contamination by elements such as hydrogen and oxygen in the solution after corrosion, leading to an increase in contact resistance. This phenomenon occurred regardless of whether graphite-like particles were embedded within the coatings. Under high-potential corrosion conditions, a noticeable transition from sp3-hybridized to sp2-hybridized carbon structures was observed.
- The integration of techniques such as magnetron sputtering, CVA, and FCVA processes can facilitate the fabrication of composite a-C coatings, which comprise a metal Ti transition layer, a dense corrosion barrier layer without embedded graphite-like carbon particles (obtained via FCVA), and a conductive surface layer containing graphite-like carbon particles (obtained using CVA). This composite coating design aims to meet the stringent requirements for long-term protection of bipolar plates under the operational conditions of PEMFCs.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
- Jiao, K.; Xuan, J.; Du, Q.; Bao, Z.; Xie, B.; Wang, B.; Zhao, Y.; Fan, L.; Wang, H.; Hou, Z.; et al. Designing the next generation of proton-exchange membrane fuel cells. Nature 2021, 595, 361–369. [Google Scholar] [CrossRef] [PubMed]
- Bi, J.; Yang, J.; Liu, X.; Wang, D.; Yang, Z.; Liu, G.; Wang, X. Development and evaluation of nitride coated titanium bipolar plates for PEM fuel cells. Int. J. Hydrogen Energy 2021, 46, 1144–1154. [Google Scholar] [CrossRef]
- Tang, A.; Crisci, L.; Bonville, L.; Jankovic, J. An overview of bipolar plates in proton exchange membrane fuel cells. J. Renew. Sustain. Energy 2021, 13, 022701. [Google Scholar] [CrossRef]
- Pozio, A.; Zaza, F.; Masci, A.; Silva, R.F. Bipolar plate materials for PEMFCs: A conductivity and stability study. J. Power Sources 2008, 179, 631–639. [Google Scholar] [CrossRef]
- Wang, H.; Sweikart, M.A.; Turner, J.A. Stainless steel as bipolar plate material for polymer electrolyte membrane fuel cells. J. Power Sources 2004, 115, 243–251. [Google Scholar] [CrossRef]
- Kim, J.S.; Peelen, W.H.A.; Hemmes, K.; Makkus, R.C. Effect of alloying elements on the contact resistance and the passivation behaviour of stainless steels. Corros. Sci. 2002, 44, 635–655. [Google Scholar] [CrossRef]
- Forouzanmehr, M.; Reza Kashyzadeh, K.; Borjali, A.; Ivanov, A.; Jafarnode, M.; Gan, T.-H.; Wang, B.; Chizari, M. Detection and Analysis of Corrosion and Contact Resistance Faults of TiN and CrN Coatings on 410 Stainless Steel as Bipolar Plates in PEM Fuel Cells. Sensors 2022, 22, 750. [Google Scholar] [CrossRef]
- Wang, L.; Youkun, T.; Zhang, Z.; Yajun, W.; Feng, Q.; Wang, H.; Li, H. Molybdenum carbide coated 316L stainless steel for bipolar plates of proton exchange membrane fuel cells. Int. J. Hydrogen Energy 2019, 44, 4940–4950. [Google Scholar] [CrossRef]
- Lu, J.L.; Abbas, N.; Tang, J.N.; Tang, J.; Zhu, G.M. Synthesis and characterization of conductive ceramic MAX-phase coatings for metal bipolar plates in simulated PEMFC environments. Corros. Sci. 2019, 158, 108106. [Google Scholar] [CrossRef]
- Bi, F.; Hou, K.; Yi, P.; Peng, L.; Lai, X. Mechanisms of growth, properties and degradation of amorphous carbon films by closed field unbalanced magnetron sputtering on stainless steel bipolar plates for PEMFCs. Appl. Surf. Sci. 2017, 422, 921–931. [Google Scholar] [CrossRef]
- Lee, S.H.; Kakati, N.; Maiti, J.; Jee, S.H.; Kalita, D.J.; Yoon, Y.S. Corrosion and electrical properties of CrN- and TiN-coated 316L stainless steel used as bipolar plates for polymer electrolyte membrane fuel cells. Thin Solid Film. 2013, 529, 374–379. [Google Scholar] [CrossRef]
- Sun, X.; Zhang, J.; Pan, W.; Wang, W.; Tang, C. Research progress in surface strengthening technology of carbide-based coating. J. Alloys Compd. 2022, 905, 164062. [Google Scholar] [CrossRef]
- Liu, R.; Jia, Q.; Zhang, B.; Lai, Z.; Chen, L. Protective coatings for metal bipolar plates of fuel cells: A review. Int. J. Hydrogen Energy 2022, 47, 22915–22937. [Google Scholar] [CrossRef]
- Su, Y.L.; Kao, W.H.; Chang, G.Y. Tribological, Anti-corrosion, and Electrical Conductivity Properties of CrCx Coatings Deposited on Stainless Steel 316L and Used as Metal Bipolar Plates for Fuel Cells. J. Mater. Eng. Perform. 2023, 32, 3739–3754. [Google Scholar] [CrossRef]
- Jin, W.; Feng, K.; Li, Z.; Cai, X.; Yu, L.D.; Zhou, D. Improvement of corrosion resistance and electrical conductivity of 304 stainless steel using close field unbalanced magnetron sputtered carbon film. J. Power Sources 2011, 196, 10032–10037. [Google Scholar] [CrossRef]
- Feng, K.; Shen, Y.; Sun, H.; Liu, D.; An, Q.; Cai, X.; Chu, P.K. Conductive amorphous carbon-coated 316L stainless steel as bipolar plates in polymer electrolyte membrane fuel cells. Int. J. Hydrogen Energy 2009, 34, 6771–6777. [Google Scholar] [CrossRef]
- Ma, Y.; Li, L.; Qian, J.; Qu, W.; Luo, R.; Wu, F.; Chen, R. Materials and structure engineering by magnetron sputtering for advanced lithium batteries. Energy Storage Mater. 2021, 39, 203–224. [Google Scholar] [CrossRef]
- Feng, K.; Guo, C.; Lin, S.-s.; Fu, Z.; Shi, Q.; Su, Y.; Wang, W.; Dai, M. Structure and properties of ta-C films prepared by vacuum cathodic arc with an unbalanced external electromagnetic field. Ceram. Int. 2021, 48, 111–119. [Google Scholar] [CrossRef]
- Toh, C.-T.; Zhang, H.; Lin, J.; Mayorov, A.S.; Wang, Y.-P.; Orofeo, C.M.; Ferry, D.B.; Andersen, H.; Kakenov, N.; Guo, Z.; et al. Synthesis and properties of free-standing monolayer amorphous carbon. Nature 2020, 577, 199–203. [Google Scholar] [CrossRef] [PubMed]
- Seok, H.-J.; Kang, Y.-j.; Kim, J.-K.; Kim, D.; Heo, S.; Kang, S.; Kim, H.-K. Tetrahedral amorphous carbon prepared filter cathodic vacuum arc for hole transport layers in perovskite solar cells and quantum dots LEDs. Sci. Technol. Adv. Mater. 2019, 20, 1118–1130. [Google Scholar] [CrossRef]
- Yi, P.; Zhang, W.; Bi, F.; Peng, L.; Lai, X. Microstructure and properties of a-C films deposited under different argon flow rate on stainless steel bipolar plates for proton exchange membrane fuel cells. J. Power Sources 2019, 410–411, 188–195. [Google Scholar] [CrossRef]
- Afshar, A.; Yari, M.; Larijani, M.M.; Eshghabadi, M. Effect of substrate temperature on structural properties and corrosion resistance of carbon thin films used as bipolar plates in polymer electrolyte membrane fuel cells. J. Alloys Compd. 2010, 502, 451–455. [Google Scholar] [CrossRef]
- Li, W.; Liu, L.-T.; Li, Z.-X.; Wang, Y.-F.; Li, H.-Z.; Lei, J.-J. Corrosion resistance and conductivity of amorphous carbon coated SS316L and TA2 bipolar plates in proton-exchange membrane fuel cells. Diam. Relat. Mater. 2021, 118, 108503. [Google Scholar] [CrossRef]
- Xu, Y.; Zhang, J.; Shi, J.R.; Ji, R.; Wang, J. The effect of carbon structure on in-situ protection for granular thin film media. Tribol. Int. 2003, 36, 325–328. [Google Scholar] [CrossRef]
- Gao, X.; Chen, J.; Xu, R.; Zhen, Z.; Zeng, X.; Chen, X.; Cui, L. Research progress and prospect of the materials of bipolar plates for proton exchange membrane fuel cells (PEMFCs). Int. J. Hydrogen Energy 2023, 50, 711–743. [Google Scholar] [CrossRef]
- Song, Y.; Zhang, C.; Ling, C.-Y.; Han, M.; Yong, R.-Y.; Sun, D.; Chen, J. Review on current research of materials, fabrication and application for bipolar plate in proton exchange membrane fuel cell. Int. J. Hydrogen Energy 2020, 45, 29832–29847. [Google Scholar] [CrossRef]
- Fogg, J.L.; Putman, K.J.; Zhang, T.; Lei, Y.; Terrones, M.; Harris, P.; Marks, N.; Suarez-Martinez, I. Catalysis-free transformation of non-graphitising carbons into highly crystalline graphite. Commun. Mater. 2020, 1, 47. [Google Scholar] [CrossRef]
- Wu, S.-D.; Chiou, A.-H. The study on a new method of preparing PMMA forming composite bipolar plate. Sci. Rep. 2021, 11, 8753. [Google Scholar] [CrossRef]
- Zhang, R.; Yang, D.; Zhu, H.; Zhang, C. Research on Potentiostatic Accelerated Test Method for Fuel Cell Metal Bipolar Plate. ECS Trans. 2019, 89, 3. [Google Scholar] [CrossRef]
- Robertson, J. Diamond-like amorphous carbon. Mater. Sci. Eng. R Rep. 2002, 37, 129–281. [Google Scholar] [CrossRef]
- Wang, Y.; Guan, W.; Fischer, C.B.; Wehner, S.; Dang, R.; Li, J.; Wang, C.; Guo, W. Microstructures, mechanical properties and tribological behaviors of amorphous carbon coatings in-situ grown on polycarbonate surfaces. Appl. Surf. Sci. 2021, 563, 150309. [Google Scholar] [CrossRef]
- Choi, J.; Ishii, K.; Kato, T.; Kawaguchi, M.; Lee, W. Structural and mechanical properties of DLC films prepared by bipolar PBII&D. Diam. Relat. Mater. 2011, 20, 845–848. [Google Scholar] [CrossRef]
- Logothetidis, S. Optical and electronic properties of amorphous carbon materials. Diam. Relat. Mater. 2003, 12, 141–150. [Google Scholar] [CrossRef]
- Lazăr, G.; Zellama, K.; Vascan, I.; Stamate, M.; Lazar, I.; Rusu, I.I. Infrared absorption properties of amorphous carbon films. J. Optoelectron. Adv. Mater. 2005, 7, 647–652. [Google Scholar]
- Fathy, M.; El-Sayed, M.; Ramzi, M.; Abdelraheem, O.H. Adsorption separation of condensate oil from produced water using ACTF prepared of oil palm leaves by batch and fixed bed techniques. Egypt. J. Pet. 2017, 27, 319–326. [Google Scholar] [CrossRef]
- Ţucureanu, V.; Matei, A.; Avram, A. FTIR Spectroscopy for Carbon Family Study. Crit. Rev. Anal. Chem. 2016, 46, 502–520. [Google Scholar] [CrossRef]
- Kahn, M.; Čekada, M.; Schöberl, T.; Berghauser, R.; Mitterer, C.; Bauer, C.; Waldhauser, W.; Brandstätter, E. Structural and mechanical properties of diamond-like carbon films deposited by an anode layer source. Thin Solid Film. 2009, 517, 6502–6507. [Google Scholar] [CrossRef]
- Rodil, S. Infrared spectra of amorphous carbon based materials. Diam. Relat. Mater. 2005, 14, 1262–1269. [Google Scholar] [CrossRef]
- Leng, Y.; Yang, D.; Ming, P.; Zhang, C. A comparative study of corrosion resistance evaluation of bipolar plate materials for proton exchange membrane fuel cell. eTransportation 2021, 10, 100139. [Google Scholar] [CrossRef]
- He, R.Y.; Jiang, J.; Wang, R.F.; Yue, Y.; Chen, Y.; Pan, T.J. Anti-corrosion and conductivity of titanium diboride coating on metallic bipolar plates. Corros. Sci. 2020, 170, 108646. [Google Scholar] [CrossRef]
- Wang, X.-Z.; Zhang, M.-M.; Hu, Q.; Su, S.; Fan, H.; Wang, H.; Luo, J. Optimizing the Interfacial Potential Distribution to Mitigate High Transient Potential Induced Dissolution on C/Ti Coated Metal Bipolar Plates Used in PEMFCs. Corros. Sci. 2022, 208, 110686. [Google Scholar] [CrossRef]
- Ren, P.; Pei, P.; Chen, D.; Zhang, L.; Li, Y.; Song, X.; Wang, M.; Wang, H. Corrosion of metallic bipolar plates accelerated by operating conditions in a simulated PEM fuel cell cathode environment. Renew. Energy 2022, 194, 1277–1287. [Google Scholar] [CrossRef]
- Okonkwo, P.C.; Belgacem, I.B.; Ige, O.O.; Emori, W.; Uzoma, P.C.; Eqbal, M.O.; Bhowmik, H. Potentiodynamic polarization test as a versatile tool for bipolar plates materials at start-up and shut-down environments: A review. Int. J. Green Energy 2021, 18, 1193–1202. [Google Scholar] [CrossRef]
- Hinds, G.; Brightman, E. Towards more representative test methods for corrosion resistance of PEMFC metallic bipolar plates. Int. J. Hydrogen Energy 2015, 40, 2785–2791. [Google Scholar] [CrossRef]
- Jung, G.; Chuang, K.-Y.; Jao, T.; Yeh, C.-C.; Lin, C.-Y. Study of high voltage applied to the membrane electrode assemblies of proton exchange membrane fuel cells as an accelerated degradation technique. Appl. Energy 2011, 100, 81–86. [Google Scholar] [CrossRef]
Sample Type | Process | P/Pa | Vbias/V | t/min | Ion Source Current/A | Arc Suoce Current/A | Power/kW | Thickness/nm |
---|---|---|---|---|---|---|---|---|
T-1 | Cleaning | 1.5 | −900 | 20 | / | / | / | / |
Ion etching | 0.8 | −600 | 20 | 5 | / | / | / | |
Ti transition layer | 0.5 | −100 | 24 | / | / | 2 | 200 | |
a-C layer | 0.2 | −200 | 18 | / | 100 | / | 800 | |
T-2 | Cleaning | 1.5 | −900 | 20 | / | / | / | / |
Ion etching | 0.8 | −600 | 20 | 5 | / | / | / | |
Ti transition layer | 0.5 | −100 | 24 | / | / | 2 | 200 | |
a-C layer | 0.005 | −2000 | 120 | / | 100 | / | 800 |
Wavenimber (cm−1) | Probable Assignment | Characteristic Vibration Mode |
---|---|---|
3400 | O-H | DLC, oxy-hydrogenated film |
3035~3085 | C-H | DLC, a-C–H, (aromatic) sp2 |
2860~2920 | C-H | DLC, a-C–H, DLC sp3 |
2180 | C≡C | DLC sp1 |
1720 | C=O | DLC contaminated with oxygen |
1600~1640, 1640 | C=C | DLC, C=C (Olefinic), sp2 |
1550~1600, 1580 | C=C | DLC, C=C (Aromatic), sp2 |
1245 | C-C | sp3/sp2 |
1100 | C-O-C | DLC contaminated with oxygen |
720 | graphite | DLC, attributable to the graphite form |
Sample Type | Self-Corrosion Potential Ecorr/V | Self-Corrosion Current Density Ecorr/μA·cm−2 |
---|---|---|
T-1 | −0.054 | 0.48 |
T-2 | −0.085 | 0.2 |
Sample Type | ID/IG | FWHM (G) | G-Peak |
---|---|---|---|
T-1 | 1.36 | 167.9 | 1566.3 |
T-2 | 1.10 | 195.3 | 1565 |
T-1—0.6 | 1.29 | 178 | 1565.3 |
T-2—0.6 | 0.92 | 204.9 | 1558 |
T-1—1.6 | 1.13 | 192.1 | 200 |
T-2—1.6 | 1.03 | 1564.7 | 1563 |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Feng, Z.; Zhou, Z.; Zeng, J.; Chen, D.; Luo, F.; Wang, Q.; Dai, W.; Zhang, R. Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques. Coatings 2024, 14, 1053. https://doi.org/10.3390/coatings14081053
Feng Z, Zhou Z, Zeng J, Chen D, Luo F, Wang Q, Dai W, Zhang R. Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques. Coatings. 2024; 14(8):1053. https://doi.org/10.3390/coatings14081053
Chicago/Turabian StyleFeng, Zhiqing, Zhetong Zhou, Junhao Zeng, Ding Chen, Fengying Luo, Qimin Wang, Wei Dai, and Ruiming Zhang. 2024. "Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques" Coatings 14, no. 8: 1053. https://doi.org/10.3390/coatings14081053