Laser-Coated Metal Fuel Cell Separators for Corrosion Resistance
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Solution Overview
Problem
Existing metal-based hydrogen fuel cell separators face challenges with corrosion resistance, increased resistance values due to oxide film formation, and high manufacturing costs, hindering their commercialization.
Innovation Solution
A method involving additive manufacturing to form a coating layer on a metal base material using Si, SiC, or a mixture of Cr and Al, which provides corrosion resistance and durability through a mixed layer and laminated flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal material is used for fuel cell separator, then strength is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining metal base material with coating layers made of Si, SiC, Cr, and Al. This creates a composite structure where the metal provides mechanical strength while the coating layers provide corrosion resistance, directly resolving the contradiction between strength and corrosion resistance.
Solution Approach 2:
The patent applies local quality by creating a coating layer with specific material composition (Si, SiC, Cr, Al) on the surface of the metal separator. The coating layer has different properties from the base metal, providing localized corrosion protection where it is most needed while maintaining the overall structural strength of the metal separator.
2Ease of manufacture
If metal material is used for fuel cell separator, then ease of manufacture is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies preliminary action by forming a protective coating layer on the metal separator surface before the separator is put into service. This pre-applied protection prevents corrosion from occurring during operation, maintaining both the ease of manufacture of metal components and the reliability against corrosion.
Solution Approach 2:
The patent combines metal base material with coating layers to create a composite structure that maintains the manufacturing advantages of metal while adding corrosion protection through the coating materials (Si, SiC, Cr, Al).
3Reliability
If coating layer is formed on metal separator, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent utilizes porous or layered coating structures formed by the additive manufacturing process. This approach provides effective corrosion protection through multiple layers and potential porosity that can be controlled, achieving good corrosion resistance while using material efficiently to control costs.
Solution Approach 2:
The patent employs additive manufacturing technology to precisely control the deposition parameters of the coating layer (material composition, layer thickness, deposition rate). This allows optimization of the coating process to achieve necessary corrosion protection at reduced material costs and manufacturing expenses compared to traditional coating methods.
4Reliability
If additive manufacturing is used to form coating layer, then corrosion resistance is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by using additive manufacturing technology that can deposit multiple coating materials (Si, SiC, Cr, Al) and create complex geometries in a single integrated process. This multi-functional approach achieves corrosion protection without requiring separate manufacturing steps for different components, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent merges the coating deposition process with the separator manufacturing process using additive manufacturing. The coating layer is formed integrally with the metal base material in a unified manufacturing operation, reducing the need for separate coating equipment and processes, thus limiting the increase in device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances corrosion resistance, durability, and economic feasibility of metal separators by forming a coating layer that maintains electrical conductivity and thermal conductivity, while also improving the efficiency per unit area.
Implementation Method 1
forming a molten pool by irradiating a laser to a surface of the metal base material
Implementation Method 2
forming a molten pool by irradiating a laser to a surface of the metal base material
Implementation Method 3
forming a coating layer using an additive manufacturing by supplying a powder made of any one of Si, SiC, and a mixture of Cr and Al to the molten pool
Data Source
AI summary
Disclosed are a method for coating metal, a metal member comprising the coating layer formed thereby, and a fuel cell separator. A method for coating metal according to an embodiment of the present invention includes preparing a metal base material; and forming a molten pool by irradiating a laser to a surface of the metal base material and forming a coating layer using an additive manufacturing by supplying a powder made of any one of Si, SiC, and a mixture of Cr and Al to the molten pool.