Nanocrystalline TaCN coated titanium bipolar plate dedicated to proton exchange membrane fuel cell

To promote the corrosion resistance and surface conductivity of metal bipolar plates (BP) in proton exchange membrane fuel cells (PEMFC), a TaCN nanoceramic coating with TaN and TaC dual phase structures was engineered onto a commercially pure titanium substrate employing the double cathode glow discharge plasma (DCGDP) technique. The as-prepared TaCN coating was well-adhered to the substrate with a thickness of ∼16.5 μm. The coating exhibited a microstructure comprising equiaxed grains with an average size of ∼10.3 nm. The electrochemical behavior of the TaCN coating was evaluated in a simulated PEMFC environment containing various HF concentrations. Open circuit potential (OCP), potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), potentiostatic polarization, and Mott-Schottky tests showed that the addition of HF enhanced the corrosion rate of both the Ti substrate and the TaCN coating. Nevertheless, the TaCN coating exhibited improved corrosion potential, lower corrosion current density and larger resistance than that of Ti for all HF concentrations. The Hilbert-Huang and corrosion morphology analysis indicated that the TaCN coating maintained a passive state with increasing HF concentration. First-principle calculations investigated the adsorption capacity of the F− ions on the passive film on the TaCN coating. Furthermore, the TaCN coating possesses desirable interfacial contact resistance (ICR) (about 10 mΩ cm2 under a compressive force of 140 N cm−2) and outstanding hydrophobicity (92.9° ± 2°). Overall, the TaCN coating, which can deliver appreciable enhancement relative to the performance of titanium, represents an extremely competitive candidate as a protective coating for bipolar plates.