Comparative study of materials for proton exchange membrane fuel cells bipolar plates: Electrical performance, durability, and automotive compatibility

Bipolar plates are essential components of proton exchange membrane fuel cells because they contribute to current transport, reactant flow distribution, heat dissipation, and overall stack durability. The present study compares metallic, graphite, and composite bipolar plate materials in terms of conductivity, corrosion resistance, mechanical behavior, and suitability for automotive applications. Metallic bipolar plates provide excellent electrical conductivity and allow compact fuel cell stack configurations, although corrosion and surface degradation may progressively increase interfacial contact resistance during operation. Composite materials reinforced with conductive nanofillers, including carbon nanotubes, demonstrate improved chemical stability, reduced interfacial resistance, and favorable weight-to-strength characteristics. Graphite-based plates remain attractive because of their high corrosion resistance and stable electrochemical properties; however, their brittle structure limits their use under severe mechanical and vibrational conditions. This work highlights the importance of balancing durability, electrical efficiency, manufacturing feasibility, and cost in the development of next-generation PEMFC bipolar plates for hydrogen transportation systems.