Among them, a core challenge is the improvement of bipolar plates (BPs). However, there are still many bottlenecking problems before the progress triumphs. The industrial applications of proton exchange membrane fuel cell (PEMFC) technology have attracted tremendous capitals and research attention in the last ten years. The modeled increase in mass transfer overpotentials with aging correlates with the initial Pt loading, ECSA loss and the initial catalyst morphology. The H-catalyst electrode showed the smallest kinetic overpotentials (ηcs ) due to higher initial Pt loading than the other two electrodes, but it had the fastest increase in ηcs with AST cycling due to lower Co retention the L-catalyst electrode showed higher ηcs due to a lower initial Pt loading, but had a smaller increase in ηcs with aging due to higher Co retention the M-catalyst electrode showed a similar increase in ηcs with aging, but this increase was due to the combined effects of Co dissolution and electrochemically active surface area (ECSA) loss.

The specific activity of the catalysts depends on their initial Co content, morphology and nanoparticle size, and remained higher than 1000 μA/cm2-Pt after 27-50% Co loss. The catalysts had different initial Co contents and nanoparticle morphologies: a 'spongy' porous morphology for the high-Co (H) content catalyst, and a fully alloyed crystalline morphology for the medium-Co (M) and low-Co (L) content catalysts. The durability of Pt-Co alloy cathode catalysts supported on high surface area carbon is investigated by subjecting them to accelerated stress tests (ASTs). However, phosphorus addition to the coating does not show to improve its properties, as deterioration of the MEA and consequently fuel cell performance losses is observed. No significant degradation of the coated surface or enhancement in metal release is observed. After electrochemical evaluation, the BPPs as well as the water effluents from the cell are examined by Scanning Electron Microscopy, Energy Dispersive and Inductively Coupled Plasma spectroscopies. The Ni-Mo coated BPP shows a low and stable ICR and the smallest effects on MEA performance, including catalyst activity/usability, cathode double layer capacitance, and membrane and ionomer resistance build up with time. The results show that all the coatings decrease the ICR in comparison to that of uncoated 316L BPP. The effect of the BPP coatings on the electrochemical performance up to 115 h is evaluated from polarization curves, cyclic voltammetry and electrochemical impedance spectroscopy together with interfacial contact resistance (ICR) measurements between the coatings and the gas diffusion layer.

The performance and durability of 316L stainless steel bipolar plates (BPP) electroplated with Ni–Mo and Ni–Mo–P coatings are investigated in a proton exchange membrane fuel cell (PEMFC), using a commercial Pt/C Nafion membrane electrode assembly (MEA). For iron-contaminated membranes, no change in cell performance was detected until the membrane conductivity loss was greater than approximately 15%. The ranking of the four transition metals tested in terms of the greatest reduction in fuel cell performance was: Al3+≫Fe2+>Ni2+, Cr3+. Membranes were immersed in metal sulfide solutions of varying concentration and then assembled into fuel cell MEAs tested in situ. Given the possible benefits of using stainless steel or aluminum for balance-of-plant components or bipolar plates, cations of Al, Fe, Ni and Cr were studied. Metal ion contamination within the membrane and the effects on fuel cell performance were investigated. One key challenge is controlling MEA contamination.

Even though great strides have been made, durability is still an issue. Automotive fuel cell technology has made considerable progress, and hydrogen fuel cell vehicles are regarded as a possible long-term solution to reduce carbon dioxide emissions, reduce fossil fuel dependency and increase energy efficiency.

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