Summary In this study, newly developed high manganese (Mn) and low nickel (Ni) austenitic stainless steels were investigated as an alternative to conventionally used SS 316L for bipolar plate applications in proton exchange membrane fuel cells. Systematic studies on the corrosion behavior were carried out in simulated hydrogen and oxygen environments, for both half‐ and fuel‐cell conditions. The Mn‐based SS revealed nobler corrosion potential and comparable passive current densities to that of SS 316L. The passive current density of Mn‐based SS is well within the DoE 2020 target of <1 μA cm−2. Though MnSS1 steel has lean Ni content, the addition of Mn and N is beneficial for improving the corrosion performance, which is comparable to SS 316L. The recorded ICR values for Mn SS1 and SS 316L are 234.6 ± 20 and 155 ± 20 mΩ cm2 at a compaction force of 140 N cm−2, respectively. Both the steels do not to meet the DoE ICR target of 10 mΩ cm2, which requires conductive coating or improvement in oxide conductivity. The performances of the steels (both Mn‐SS and 316L SS) with varying thickness were also investigated in a single fuel cell condition with serpentine flow field design as bipolar plates with varying thickness (10, 5 and 2 mm). A maximum power density of 370 mW cm−2 was achieved with the Mn‐based metallic bipolar plates, whereas SS 316L showed 354 mW cm−2. By changing the composition of austenitic stainless steel, that is, using Mn SS1 instead of SS 316L the overall fuel cell cost decreases by three times.

Influence of composition, specifically manganese and nitrogen content, on the microstructure associated corrosion resistance property of newly developed stainless steel has been studied. The developed steels have been characterised for their microstructure, mechanical and electrochemical properties.The results indicate that the addition of manganese and nitrogen as a substitute for nickel favours the austenite microstructure, higher yield strength (> 350 MPa), tensile strength (> 700 MPa), elongation and superior Charpy Vnotch impact toughness properties. The results obtained from electrochemical tests such as potentiodynamic polarisation and electrochemical impedance spectroscopy of manganese stainless steel show remarkable improvement (about 4 times) in corrosion resistance exhibiting passivity behaviour like that of commercial stainless steel (316L).

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