Mechanochemistry-Enabled Transition Metal Carbides for a New Generation of Cost-Efficient and Durable Fuel Cell Bipolar Plates

Metallic bipolar plates are a key component of PEM fuel-cell stacks, combining high electrical conductivity with the potential for cost-efficient, scalable manufacturing. However, their long-term performance depends on protective coatings that provide both low electrical contact resistance and effective corrosion protection under demanding fuel-cell operating conditions.

MechSyn is developing mechanochemically produced transition metal carbides as advanced coating materials for stainless-steel bipolar plates. The project focuses on chromium carbide (Cr₃C₂) as the lead material, complemented by molybdenum carbide (Mo₂C) as a development candidate.

MechSyn’s mechanochemical synthesis route enables carbide production at room temperature and ambient pressure without solvents, providing an alternative to conventional carbide synthesis processes requiring temperatures above 1,400°C. Initial results for mechanochemically produced Cr₃C₂ demonstrate an electrical conductivity of 6.7 × 10⁶ S/m, which is around 300x higher than conventional Cr₃C₂, while coated stainless-steel bipolar plates have achieved interfacial contact resistance below 10 mΩ·cm² under application-relevant testing conditions.

The project aims to scale up material production up to kg scale, optimise carbide-based coating formulations and validate electrical performance, corrosion resistance and durability under fuel-cell-relevant conditions. The objective is to advance the technology from TRL 6 towards TRL 7 and establish the material specifications, quality-control procedures and manufacturing parameters required for subsequent industrial qualification and commercial deployment.

MechSyn is particularly interested in engaging with fuel-cell manufacturers, bipolar-plate producers, coating specialists and other industrial partners to discuss performance requirements, qualification procedures and potential validation or commercialisation pathways.