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A Review on Thermal Coupling of Metal Hydride Storage Tanks with Fuel Cells and Electrolyzers
Dec 2022
Publication
Hydrogen is one of the energy carriers that has started to play a significant role in the clean energy transition. In the hydrogen ecosystem storing hydrogen safely and with high volumetric density plays a key role. In this regard metal hydride storage seems to be superior to compressed gas storage which is the most common method used today. However thermal management is a challenge that needs to be considered. Temperature changes occur during charging and discharging processes due to the reactions between metal metal hydride and hydrogen which affect the inflow or outflow of hydrogen at the desired flow rate. There are different thermal management techniques to handle this challenge in the literature. When the metal hydride storage tanks are used in integrated systems together with a fuel cell and/or an electrolyzer the thermal interactions between these components can be used for this purpose. This study gives a comprehensive review of the heat transfer during the charging and discharging of metal hydride tanks the thermal management system techniques used for metal hydride tanks and the studies on the thermal management of metal hydride tanks with material streams from the fuel cell and/or electrolyzers.
Optimization and Sustainability of Gasohol/hydrogen Blends for Operative Spark Ignition Engine Utilization and Green Environment
Aug 2022
Publication
One of the many technical benefits of green diesel (GD) is its ability to be oxygenated lubricated and adopted in diesel engines without requiring hardware modifications. The inability of GD to reduce exhaust tail emissions and its poor performance in endurance tests have spurred researchers to look for new clean fuels. Improving gasohol/hydrogen blend (GHB) spark ignition is critical to its long-term viability and accurate demand forecasting. This study employed the Response Surface Methodology (RSM) to identify the appropriate GHB and engine speed (ES) for efficient performance and lower emissions in a GHB engine. The RSM model output variables included brake specific fuel consumption (BSFC) brake thermal efficiency (BTE) hydrocarbon (HC) carbon dioxide (CO2) and carbon monoxide (CO) while the input variables included ES and GHB. The Analysis of Variance-assisted RSM revealed that the most affected responses are BSFC and BTE. Based on the desirability criteria the best values for the GHB and the ES were determined to be 20% and 1500 rpm respectively while the validation between experimental and numerical results was calculated to be 4.82. As a result the RSM is a useful tool for predicting the optimal GHB and ES for optimizing spark-ignition engine characteristics and ensuring benign environment.
Portable Prototype of Hydrogen Fuel Cells for Educational Training
Jan 2023
Publication
This paper presents an experimental prototype of hydrogen fuel cells suitable for training engineering students. The presented system is designed to teach students the V-I characteristics of the fuel cells and how to record the V-I characteristics curve in the case of a single or multiple fuel cells. The prototype contains a compact electrolyzer to produce hydrogen and oxygen to the fuel cell. The fuel cell generates electricity to supply power to various types of loads. The paper also illustrates how to calculate the efficiency of fuel cells in series and parallel modes of operation. In the series mode of operation it is mathematically proven that the efficiency is higher at lower currents. Still the fuel cell operating area is required where the power is the highest. According to experimental results the efficiency in the case of series connection is approximately 25% while in parallel operation mode the efficiency is about 50%. Thus a parallel connection is recommended in the high current applications because the efficiency is higher than the one resulted from series connection. As explained later in the study plan several other experiments can be performed using this educational kit.
Carbon Footprint Enhancement of an Agricultural Telehandler through the Application of a Fuel Cell Powertrain
Mar 2024
Publication
The growing awareness about climate change and environmental pollution is pushing the industrial and academic world to investigate more sustainable solutions to reduce the impact of anthropic activities. As a consequence a process of electrification is involving all kind of vehicles with a view to gradually substitute traditional powertrains that emit several pollutants in the exhaust due to the combustion process. In this context fuel cell powertrains are a more promising strategy with respect to battery electric alternatives where productivity and endurance are crucial. It is important to replace internal combustion engines in those vehicles such as the those in the sector of NonRoad Mobile Machinery. In the present paper a preliminary analysis of a fuel cell powertrain for a telehandler is proposed. The analysis focused on performance fuel economy durability applicability and environmental impact of the vehicle. Numerical models were built in MATLAB/Simulink and a simple power follower strategy was developed with the aim of reducing components degradation and to guarantee a charge sustaining operation. Simulations were carried out regarding both peak power conditions and a typical real work scenario. The simulations’ results showed that the fuel cell powertrain was able to achieve almost the same performances without excessive stress on its components. Indeed a degradation analysis was conducted showing that the fuel cell system can achieve satisfactory durability. Moreover a Well-to-Wheel approach was adopted to evaluate the benefits in terms of greenhouse gases of adopting the fuel cell system. The results of the analysis demonstrated that even if considering grey hydrogen to feed the fuel cell system the proposed powertrain can reduce the equivalent CO2 emissions of 69%. This reduction can be further enhanced using hydrogen from cleaner production processes. The proposed preliminary analysis demonstrated that fuel cell powertrains can be a feasible solution to substitute traditional systems on off-road vehicles even if a higher investment cost might be required.
A Novel Approach for Quantifying Hydrogen Embrittlement Using Side-grooved CT Samples
Feb 2022
Publication
Aerospace parts made of high strength steels such as landing gears and helicopter transmissions are often electroplated to satisfy various engineering specifications. However plated parts are occasionnaly rejected because of hydrogen embrittlement and the industry has few means of evaluating quantitatively the actual damage caused by hydrogen. In the present article we developed a novel method to measure the stress intensity threshold for hydrogen embrittlement (Kth) in industrial plating conditions. The method consists in plating side-grooved CT samples in industrial plating baths and measuring Kth with an incremental step loading methodology. We validated the method with a benchmark case known to produce embrittlement (omitted post-plating bake) and we used the method on a test case for which the level of embrittlement was unknown (delayed bake). For the benchmark case we measured a Kth of 49.0 MPa m0.5 for non-baked samples. This value is significantly lower than the fracture toughness of the unplated material which is 63.8 MPa m0.5 . We conclude that this novel combination of geometry and test method is efficient in quantifying hydrogen embrittlement of samples plated in industrial conditions. For the test case the Kth are respectively 57.9 MPa m0.5 and 58.8 MPa m0.5 for samples baked 100 h and 4 h after plating. We conclude that delaying the post-plating bake does not cause hydrogen embrittlement in the studied conditions. Using a finite element hydrogen diffusion analysis we argue that the side grooves on CT samples increase the sensitivity to hydrogen embrittlement in comparison to smooth samples. In smooth samples a zone of plane stress at the surface of the specimen shields hydrogen from penetrating to the center of the specimen a phenomenon which is alleviated with machining side grooves.
Hydrogen Towards Sustainable Transition: A Review of Production, Economic, Environmental Impact and Scaling Factors
Sep 2023
Publication
Currently meeting the global energy demand is largely dependent on fossil fuels such as natural gas coal and oil. Fossil fuels represent a danger to the Earth’s environment and its biological systems. The utilisation of these fuels results in a rise in atmospheric CO2 levels which in turn triggers global warming and adverse changes in the climate. Furthermore these represent finite energy resources that will eventually deplete. There is a pressing need to identify and harness renewable energy sources as a replacement for fossil fuels in the near future. This shift is expected to have a minimal environmental impact and would contribute to ensuring energy security. Hydrogen is considered a highly desirable fuel option with the potential to substitute depleting hydrocarbon resources. This concise review explores diverse methods of renewable hydrogen production with a primary focus on solar wind geothermal and mainly water-splitting techniques such as electrolysis thermolysis photolysis and biomass-related processes. It addresses their limitations and key challenges hampering the global hydrogen economy’s growth including clean value chain creation storage transportation production costs standards and investment risks. The study concludes with research recommendations to enhance production efficiencies and policy suggestions for governments to mitigate investment risks while scaling up the hydrogen economy.
Integration of Renewable Hydrogen Production in Steelworks Off-Gases for the Synthesis of Methanol and Methane
May 2021
Publication
The steel industry is among the highest carbon-emitting industrial sectors. Since the steel production process is already exhaustively optimized alternative routes are sought in order to increase carbon efficiency and reduce these emissions. During steel production three main carbon-containing off-gases are generated: blast furnace gas coke oven gas and basic oxygen furnace gas. In the present work the addition of renewable hydrogen by electrolysis to those steelworks off-gases is studied for the production of methane and methanol. Different case scenarios are investigated using AspenPlusTM flowsheet simulations which differ on the end-product the feedstock flowrates and on the production of power. Each case study is evaluated in terms of hydrogen and electrolysis requirements carbon conversion hydrogen consumption and product yields. The findings of this study showed that the electrolysis requirements surpass the energy content of the steelwork’s feedstock. However for the methanol synthesis cases substantial improvements can be achieved if recycling a significant amount of the residual hydrogen.
Does Time Matter? A Multi-level Assessment of Delayed Energy Transitions and Hydrogen Pathways in Norway
Mar 2023
Publication
The Russian invasion of Ukraine has undeniably disrupted the EU's energy system and created a window of opportunity for an acceleration of the low-carbon energy transition in Europe. As the trading bloc's biggest gas supplier Norway faces the imminent threat of fast-depleting gas reserves and declining value for its exports. Norway is trying to beat the clock by aggressively exploring more petroleum therefore delaying its energy transition. In anticipation of the future drop in gas prices Norway is counting on blue hydrogen to valorise its gas resources before gradually shifting to green hydrogen export. Against this background this article seeks to understand how changes in the EU's energy landscape have affected the energy export sector and low-carbon hydrogen export developments in Norway from a multi-level perspective. Using the exploratory scenario approach the article assesses the implications of the different petroleum exploration outcomes on the development of the low-carbon hydrogen export market in Norway. The findings show that despite gas discoveries there is an urgent need for a phase-out plan for the Norwegian petroleum sector. For low-carbon hydrogen to play an important role in Norway's energy transition time is of the essence and action needs to be taken during this window of opportunity. An industrial sector and its value chain could take 25 years to transform which means that actions and policies for a full transformation pathway need to take place in Norway by 2025 to be ready for a climate-neutral Europe in 2050.
Technology Transfer from Fuel Processing for Fuel Cells to Fuel Synthesis from Hydrogen and Carbon Dioxide
Aug 2023
Publication
Improving the energy efficiency of existing technologies such as the on-board power supply of trucks ships and aircraft is an important endeavor for reducing primary energy consumption. The approach consists of using fuel cell technology in conjunction with hydrogen production from liquid fuels. However the energy transition with the goal of complete climate-neutrality requires technological changes in the use of hydrogen produced from renewable energy via electrolysis. Synthetic fuels are an important building block for drive systems that will continue to require liquid energy carriers in the future due to their range. This study addresses the question of whether technical devices that were developed for the generation of hydrogen from liquid fuels for fuel cells to generate electricity are now suitable for the reverse process chain or can play an important role in it. The new process chain produces hydrogen from sustainable electricity combining it with carbon dioxide to create a synthetic liquid fuel.
Cryogenic Hydrogen Jet and Flame for Clean Energy Applications: Progress and Challenges
May 2023
Publication
Industries across the world are making the transition to net-zero carbon emissions as government policies and strategies are proposed to mitigate the impact of climate change on the planet. As a result the use of hydrogen as an energy source is becoming an increasingly popular field of research particularly in the aviation sector where an alternative green renewable fuel to the traditional hydrocarbon fuels such as kerosene is essential. Hydrogen can be stored in multiple ways including compressed gaseous hydrogen cryo-compressed hydrogen and cryogenic liquid hydrogen. The infrastructure and storage of hydrogen will play a pivotal role in the realisation of large-scale conversion from traditional fuels with safety being a key consideration. This paper provides a review on previous work undertaken to study the characterisation of both unignited and ignited hydrogen jets which are fundamental phenomena for the utilisation of hydrogen. This includes work that focuses on the near-field flow structure dispersion in the far-field ignition and flame characteristics with multi-physics. The safety considerations are also included. The theoretical models and computational fluid dynamics (CFD) multiphase and reactive flow approaches are discussed. Then an overview of previous experimental work is provided before focusing the review on the existing computational results with comparison to experiments. Upon completion of this review it is highlighted that the complex near-field physics and flow phenomena are areas lacking in research. The near-field flow properties and characteristics are of significant importance with respect to the ignition and combustion of hydrogen.
Decarbonization of the Steel Industry: A Techno-economic Analysis
Jan 2022
Publication
A substantial CO2-emmissions abatement from the steel sector seems to be a challenging task without support of so-called “breakthrough technologies” such as the hydrogen-based direct reduction process. The scope of this work is to evaluate both the potential for the implementation of green hydrogen generated via electrolysis in the direct reduction process as well as the constraints. The results for this process route are compared with both the well-established blast furnace route as well as the natural gas-based direct reduction which is considered as a bridge technology towards decarbonization as it already operates with H2 and CO as main reducing agents. The outcomes obtained from the operation of a 6-MW PEM electrolysis system installed as part of the H2FUTURE project provide a basis for this analysis. The CO2 reduction potential for the various routes together with an economic study are the main results of this analysis. Additionally the corresponding hydrogen- and electricity demands for large-scale adoption across Europe are presented in order to rate possible scenarios for the future of steelmaking towards a carbon-lean industry.
Islanded Ammonia Power Systems: Technology Review & Conceptual Process Design
Aug 2019
Publication
Recent advances in technologies for the decentralized islanded ammonia economy are reviewed with an emphasis on feasibility for long-term practical implementation. The emphasis in this review is on storage systems in the size range of 1–10 MW. Alternatives for hydrogen production nitrogen production ammonia synthesis ammonia separation ammonia storage and ammonia combustion are compared and evaluated. A conceptual process design based on the optimization of temperature and pressure levels of existing and recently proposed technologies is presented for an islanded ammonia energy system. This process design consists of wind turbines and solar panels for electricity generation a battery for short-term energy storage an electrolyzer for hydrogen production a pressure swing adsorption unit for nitrogen production a novel ruthenium-based catalyst for ammonia synthesis a supported metal halide for ammonia separation and storage and an ammonia fueled proton-conducting solid oxide fuel cell for electricity generation. In a generic location in northern Europe it is possible to operate the islanded energy system at a round-trip efficiency of 61% and at a cost of about 0.30–0.35 € kWh−1 .
Research Progress and Prospects on Hydrogen Damage in Welds of Hydrogen-Blended Natural Gas Pipelines
Nov 2023
Publication
Hydrogen energy represents a crucial pathway towards achieving carbon neutrality and is a pivotal facet of future strategic emerging industries. The safe and efficient transportation of hydrogen is a key link in the entire chain development of the hydrogen energy industry’s “production storage and transportation”. Mixing hydrogen into natural gas pipelines for transportation is the potential best way to achieve large-scale long-distance safe and efficient hydrogen transportation. Welds are identified as the vulnerable points in natural gas pipelines and compatibility between hydrogen-doped natural gas and existing pipeline welds is a critical technical challenge that affects the global-scale transportation of hydrogen energy. Therefore this article systematically discusses the construction and weld characteristics of hydrogen-doped natural gas pipelines the research status of hydrogen damage mechanism and mechanical property strengthening methods of hydrogen-doped natural gas pipeline welds and points out the future development direction of hydrogen damage mechanism research in hydrogen-doped natural gas pipeline welds. The research results show that: 1 Currently there is a need for comprehensive research on the degradation of mechanical properties in welds made from typical pipe materials on a global scale. It is imperative to systematically elucidate the mechanism of mechanical property degradation due to conventional and hydrogeninduced damage in welds of high-pressure hydrogen-doped natural gas pipelines worldwide. 2 The deterioration of mechanical properties in welds of hydrogen-doped natural gas pipelines is influenced by various components including hydrogen carbon dioxide and nitrogen. It is necessary to reveal the mechanism of mechanical property deterioration of pipeline welds under the joint participation of multiple damage mechanisms under multi-component gas conditions. 3 Establishing a fundamental database of mechanical properties for typical pipeline steel materials under hydrogen-doped natural gas conditions globally is imperative to form a method for strengthening the mechanical properties of typical high-pressure hydrogen-doped natural gas pipeline welds. 4 It is essential to promptly develop relevant standards for hydrogen blending transportation welding technology as well as weld evaluation testing and repair procedures for natural gas pipelines.
Influence of Natural Gas and Hydrogen Properties on Internal Combustion Engine Performance, Combustion, and Emissions: A Review
Jan 2024
Publication
This paper provides a comprehensive overview of the physical properties and applications of natural gas (NG) and hydrogen as fuels in internal combustion (IC) engines. The paper also meticulously examines the use of both NG and hydrogen as a fuel in vehicles their production physical characteristics and combustion properties. It reviews the current experimental studies in the literature and investigates the results of using both fuels. It further covers the challenges associated with injectors needle valves lubrication spark plugs and safety requirements for both fuels. Finally the challenges related to the storage production and safety of both fuels are also discussed. The literature review reveals that NG in spark ignition (SI) engines has a clear and direct positive impact on fuel economy and certain emissions notably reducing CO2 and non-methane hydrocarbons. However its effect on other emissions such as unburnt hydrocarbons (UHC) nitrogen oxides (NOx) and carbon monoxide (CO) is less clear. NG which is primarily methane has a lower carbon-to-hydrogen ratio than diesel fuel resulting in lower CO2 emissions per unit of energy released. In contrast hydrogen is particularly well-suited for use in gasoline engines due to its high self-ignition temperature. While increasing the hydrogen content of NG engines reduces torque and power output higher hydrogen input results in reduced fuel consumption and the mitigation of toxic exhaust emissions. Due to its high ignition temperature hydrogen is not inherently suitable for direct use in diesel engines necessitating the exploration of alternative methods for hydrogen introduction into the cylinder. The literature review suggests that hydrogen in diesel engines has shown a reduction in specific exhaust emissions and fuel consumption and an increase in NOx emissions. Overall the paper provides a valuable and informative overview of the challenges and opportunities associated with using hydrogen and NG as fuels in IC engines. It highlights the need for further research and development to address the remaining challenges such as the development of more efficient combustion chambers and the reduction of NOx emissions.
Sustainable Hydrogen Production from Seawater Electrolysis: Through Fundamental Electrochemical Principles to the Most Recent Development
Nov 2022
Publication
Among the many potential future energy sources hydrogen stands out as particularly promising. Because it is a green and renewable chemical process water electrolysis has earned much interest among the different hydrogen production techniques. Seawater is the most abundant source of water and the ideal and cheapest electrolyte. The first part of this review includes the description of the general theoretical concepts: chemical physical and electrochemical that stands on the basis of water electrolysis. Due to the rapid development of new electrode materials and cell technology research has focused on specific seawater electrolysis parameters: the cathodic evolution of hydrogen; the concurrent anodic evolution of oxygen and chlorine; specific seawater catalyst electrodes; and analytical methods to describe their catalytic activity and seawater electrolyzer efficiency. Once the specific objectives of seawater electrolysis have been established through the design and energy performance of the electrolyzer the study further describes the newest challenges that an accessible facility for the electrochemical production of hydrogen as fuel from seawater must respond to for sustainable development: capitalizing on known and emerging technologies; protecting the environment; utilizing green renewable energies as sources of electricity; and above all economic efficiency as a whole.
Mapping the Future of Green Hydrogen: Integrated Analysis of Poland and the EU’s Development Pathways to 2050
Aug 2023
Publication
This article presents the results of a comparative scenario analysis of the “green hydrogen” development pathways in Poland and the EU in the 2050 perspective. We prepared the scenarios by linking three models: two sectoral models for the power and transport sectors and a Computable General Equilibrium model (d-Place). The basic precondition for the large-scale use of hydrogen in both Poland and in European Union countries is the pursuit of ambitious greenhouse gas reduction targets. The EU plans indicate that the main source of hydrogen will be renewable energy (RES). “Green hydrogen” is seen as one of the main methods with which to balance energy supply from intermittent RES such as solar and wind. The questions that arise concern the amount of hydrogen required to meet the energy needs in Poland and Europe in decarbonized sectors of the economy and to what extent can demand be covered by internal production. In the article we estimated the potential of the production of “green hydrogen” derived from electrolysis for different scenarios of the development of the electricity sector in Poland and the EU. For 2050 it ranges from 76 to 206 PJ/y (Poland) and from 4449 to 5985 PJ/y (EU+). The role of hydrogen as an energy storage was also emphasized highlighting its use in the process of stabilizing the electric power system. Hydrogen usage in the energy sector is projected to range from 67 to 76 PJ/y for Poland and from 1066 to 1601 PJ/y for EU+ by 2050. Depending on the scenario this implies that between 25% and 35% of green hydrogen will be used in the power sector as a long-term energy storage.
The Role of Electricity-based Hydrogen in the Emerging Power-to-X Economy
Aug 2023
Publication
As energy system research into high shares of renewables has developed so have the perspectives of the fundamental nature of a highly renewable economy. Early energy system transition research suggested that current fossil fuel energy systems would transition to a ‘Hydrogen Economy’ whereas more recent insights suggest that a ‘Power-to-X Economy’ may be a more appropriate term as renewable electricity will become both the most important primary and final energy carrier through various Power-to-X conversion routes across the energy system. This paper provides a detailed overview on research insights of recent years on the core elements of the Power-to-X Economy and the role of hydrogen based on latest research results. These results suggest that by 2050 upwards of 61737 TWhLHV of hydrogen will be required to fully defossilise the global energy-industry system. Hydrogen therefore emerges as a central intermediate energy carrier and its relevance is driven by significant cost reductions in renewable electricity especially of solar photovoltaics and wind power. Efficiency and cost drivers position direct electrification as the primary solution for defossilisation of the global energy-industry system; however electron-to-molecule routes are essential for the large subset of remaining energy-related demands including chemical production marine and aviation fuels and steelmaking.
Decarbonizing the Spanish Transportation Sector by 2050: Design and Techno-economic Assessment of the Hydrogen Generation and Supply Chain
May 2023
Publication
The transport sector is difficult to decarbonize due to its high reliance on fossil fuels accounting for 37% of global end-use sectors emissions in 2021. Therefore this work proposes an energy model to replace the Spanish vehicle fleet by hydrogen-fueled vehicles by 2050. Thus six regions are defined according to their proximity to regasification plants where hydrogen generation hubs are implemented. Likewise renewables deployment is subject to their land availability. Hydrogen is transported through an overhauled primary natural gas transport network while two distribution methods are compared for levelized cost of hydrogen minimization: gaseous pipeline vs liquid hydrogen supply in trucks. Hence a capacity of 443.1 GW of renewables 214 GW of electrolyzers and 3.45 TWh of hydrogen storage is required nationwide. Additionally gaseous hydrogen distribution is on average 17% cheaper than liquid hydrogen delivery. Finally all the regions present lower prices per km traveled than gasoline or diesel.
H2-powered Aviation at Airports – Design and Economics of LH2 Refueling Systems
Feb 2022
Publication
In this paper the broader perspective of green hydrogen (H2) supply and refueling systems for aircraft is provided as an enabling technology brick for more climate friendly H2-powered aviation. For this two H2 demand scenarios at exemplary airports are determined for 2050. Then general requirements for liquid hydrogen (LH2) refueling setups in an airport environment are derived and techno-economic models for LH2 storage liquefaction and transportation to the aircraft are designed. Finally a cost tradeoff study is undertaken for the design of the LH2 setup including LH2 refueling trucks and a LH2 pipeline and hydrant system. It is found that for airports with less than 125 ktLH2 annual demand a LH2 refueling truck setup is the more economic choice. At airports with higher annual LH2 demands a LH2 pipeline & hydrant system can lead to slight cost reductions and enable safer and faster refueling. However in all demand scenarios the refueling system costs only mark 3 to 4% of the total supply costs of LH2. The latter are dominated by the costs for green H2 produced offsite followed by the costs for liquefaction of H2 at an airport. While cost reducing scaling effects are likely to be achieved for H2 liquefaction plants other component capacities would already be designed at maximum capacities for medium-sized airports. Furthermore with annual LH2 demands of 100 ktLH2 and more medium and larger airports could take a special H2 hub role by 2050 dominating regional H2 consumption. Finally technology demonstrators are required to reduce uncertainty around major techno-economic parameters such as the investment costs for LH2 pipeline & hydrant systems.
Thermal Sprayed Protective Coatings for Bipolar Plates of Hydrogen Fuel Cells and Water Electrolysis Cells
Mar 2024
Publication
As one core component in hydrogen fuel cells and water electrolysis cells bipolar plates (BPs) perform multiple important functions such as separating the fuel and oxidant flow providing mechanical support conducting electricity and heat connecting the cell units into a stack etc. On the path toward commercialization the manufacturing costs of bipolar plates have to be substantially reduced by adopting low-cost and easy-to-process metallic materials (e.g. stainless steel aluminum or copper). However these materials are susceptible to electrochemical corrosion under harsh operating conditions resulting in long-term performance degradation. By means of advanced thermal spraying technologies protective coatings can be prepared on bipolar plates so as to inhibit oxidation and corrosion. This paper reviews several typical thermal spraying technologies including atmospheric plasma spraying (APS) vacuum plasma spraying (VPS) and high-velocity oxygen fuel (HVOF) spraying for preparing coatings of bipolar plates particularly emphasizing the effect of spraying processes on coating effectiveness. The performance of coatings relies not only on the materials as selected or designed but also on the composition and microstructure practically obtained in the spraying process. The temperature and velocity of in-flight particles have a significant impact on coating quality; therefore precise control over these factors is demanded.
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