Progress and Perspectives on Metallic Bipolar Plates in Fuel Cells

doi:10.11900/0412.1961.2025.00142

Acta Metall Sin

2026, Vol. 62

Issue (2): 263-274 DOI: 10.11900/0412.1961.2025.00142

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Progress and Perspectives on Metallic Bipolar Plates in Fuel Cells

LUO Haiwen(

), LIN Xiong, LIU Gaoyang, HU Bin(

)

School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China

Cite this article:

LUO Haiwen, LIN Xiong, LIU Gaoyang, HU Bin. Progress and Perspectives on Metallic Bipolar Plates in Fuel Cells. Acta Metall Sin, 2026, 62(2): 263-274.

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Abstract

With the advancement of the global carbon neutrality strategy, proton exchange membrane fuel cells (PEMFCs), a typical type of low-temperature fuel cell, have been widely applied in transportation power systems, portable power equipment, and distributed energy systems because of their notable technical advantages, including high energy conversion efficiency (> 60%), low operating temperatures (60-80 ^oC), and near-zero carbon dioxide emissions. As a key fuel cell component, the bipolar plate serves several essential functions, including gas distribution, electron conduction, and management of reactant flow fields. The corrosion resistance and electrical conductivity of bipolar plates directly determine overall fuel cell performance, including energy conversion efficiency, durability, and manufacturing cost. Therefore, bipolar plates with high corrosion resistance and high conductivity for PEMFCs have recently been the focus of intensive research. This study reviews various metallic bipolar plates, their surface modification strategies, and the resulting performance, including Al/Ti alloys and austenitic/ferritic stainless steels. Both Al and Ti alloys require noble metal coatings, such as Au/Ni-P and CrN, to balance corrosion resistance and conductivity, leading to high costs and complex fabrication processes that hinder commercialization. Although the corrosion resistance of austenitic stainless steels can be enhanced through synergistic Cr/Mo alloying, the rapid thickening of the passivation layer leads to excessively high interfacial contact resistance during service. In contrast, ferritic stainless steels are prone to intergranular corrosion; however, this can be mitigated through ultralow carbon content and stabilization by Ti/Nb microalloying. Their application in bipolar plates remains constrained because of poor formability and corrosion current densities in the uncoated state that often exceed the target values set by the United States Department of Energy. Although surface coating technologies, such as CrN and conductive polymers, can improve corrosion resistance and conductivity, process complexity and coating durability remain major concerns. Furthermore, this paper introduces a novel alloying strategy for high-Cr ferritic stainless steels used as coating-free bipolar plates, which simultaneously achieves excellent ductility, high corrosion resistance, and high electrical conductivity under simulated PEMFC conditions. Finally, future development directions for PEMFC bipolar plate materials are discussed.

Key words: proton exchange membrane fuel cell (PEMFC) bipolar plate material ferritic stainless steel corrosion resistance-electrical conductivity synergy optimization

Received: 27 May 2025

ZTFLH:

TM911.4

Fund: China Baowu Low Carbon Metallurgy Innovation Foundation(BWLCF202213)

Corresponding Authors: LUO Haiwen, professor, Tel: (010)62332911, E-mail: luohaiwen@ustb.edu.cn;
HU Bin, associate professor, Tel: (010)62332911, E-mail: hubin@ustb.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00142 OR https://www.ams.org.cn/EN/Y2026/V62/I2/263

Fig.1 Schematic of proton exchange membrane fuel cell (PEMFC) stack structure (a: clamping plate, b: end plate, c: sealing gasket, d: gas diffusion layer, e: catalyst layer, f: bipolar plate, g: repeating unit assembly)

Table 1 Performance targets for bipolar plates established by the U.S. Department of Energy (DOE) in 2020

Table 2 Electrochemical characteristics of Al alloy substrates and coatings^[10-17]

Table 3 Electrochemical characteristics of Ti alloy substrates and coatings^[18-21]

Table 4 Chemical compositions of austenitic stainless steels^[34-36]

Table 5 i_corr and ICR of uncoated austenitic stainless steels^[36,41]

Table 6 Electrochemical characteristics of stainless steel substrates and coatings^[42-55]

Table 7 Chemical compositions of ferritic stainless steels^[58-62]

Fig.2 Anodic (a) and cathodic (b) polarization behaviors of different ferritic stainless steels^[58]; interfacial contact resistance of 446M stainless steel with varying surface roughness (c)^[60]; interfacial contact resistance of 446M stainless steel after different surface treatments (d)^[68] and EDS analysis of Cu precipitation on the surface of 446M stainless steel (e)^[68] (CD—current density, SCE—saturated calomel electrode)

Table 8 i_corr, ICR, and elongations of uncoated ferritic stainless steels^{[58,59,62,69,70]}

Fig.3 Corrosion resistances in a simulated PEMFC acidic medium (potentiodynamic polarization curves) (a) and effects of compaction force on the interface contact resistance (b) of our newly developed Ru-containing ferritic stainless steel (Steel-Ru) (RHE—reversible hydrogen electrode, i—current density, E—potential)

Fig.4 Comparisons of tensile properties (a) and the service performance including ICR and i_corr (b) between our newly developed Steel-Ru for bipolar plates and the existing commercial ferritic stainless steels, the latter were measured in the un-coated state

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