Corrosion-resistant and conductive Ti-Nb-O coatings tailored for ultra-low Pt-loaded BPPs and PTLs in PEM electrolyzers
Abstract
We develop highly corrosion-resistant and conductive Ti-Nb-O coatings for metallic components -- bipolar plates (BPPs) and porous transport layers (PTLs) -- in PEM water electrolyzers. Using reactive high-power impulse magnetron sputtering (HiPIMS), we deposit compact 200 nm bilayer coatings onto SS316L substrates, systematically tailoring their composition. By precisely controlling oxygen partial pressure and Nb/Ti ratio, we adjust stoichiometry and structure, directly affecting electrical resistivity and corrosion resistance. We examine interfacial contact resistance (ICR) and electrochemical parameters before and after accelerated corrosion testing. Optimized coatings exhibit resistivity on the order of 10-4 Ohmcm and extremely low corrosion current densities (Jcorr = 0.01-0.08 uA/cm2), well below the U.S. DOE 2026 target. Most importantly, these coatings enable the ICR target after accelerated corrosion testing with a Pt overlayer as thin as 5 nm, reducing Pt loading by up to two orders of magnitude compared to conventional approaches.
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