Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques

This study explores the utilization of cathodic vacuum arc (CVA) technology to address the limitations of magnetron sputtering technology in preparing amorphous carbon (a-C) coatings, such as having a low ionization rate, low deposition rate, and insufficiently dense structure. Specifically, a-C coatings were prepared by the cathodic vacuum arc (CVA)and the filtered cathodic vacuum arc (FCVA) technology,, one with embedded carbon particles and one without, both having closely related carbon structures. Research is currently underway on bipolar plate coatings for fuel cells. The corrosion behavior of the prepared a-C coatings was examined through Tafel polarization analysis under simulated fuel cell operating conditions as well as potentiostatic analysis at 0.6 V under normal conditions and 1.6 V under start–stop conditions for 7200 s. The coatings before and after corrosion are characterized using scanning electron microscopy, energy-dispersive X-ray spectroscopy, Raman spectroscopy, and infrared spectroscopy. The results reveal that the incorporation of conductive graphite-like particles in the coatings reduces their contact resistance. However, the gaps between these particles and the coatings act as pathways for corrosive solution, exacerbating the corrosion of the coatings. After corrosion at 0.6 V, both sets of coatings with sp2-hybridized carbon structures are contaminated by elements such as hydrogen and oxygen, leading to an increase in their contact resistance. Under high potential conditions (1.6 V), large corrosion pits and defects appear at the locations of graphite-like carbon particles. Furthermore, both sets of samples exhibit more severe oxygen contamination and a transformation of broken carbon bonds from sp3- to sp2-hybridized forms, irrespective of whether embedded graphite particles are present.