Hydrogen produced via water electrolysis powered by renewable electricity or green H2 offers new decarbonization pathways. Proton exchange membrane water electrolysis (PEMWE) is a promising technology although the current density, temperature, and H2 pressure of the PEMWE will have to be increased substantially to curtail the cost of green H2. Here, a porous transport layer for PEMWE is reported, that enables operation at up to 6 A cm−2, 90 °C, and 90 bar H2 output pressure. It consists of a Ti porous sintered layer (PSL) on a low‐cost Ti mesh (PSL/mesh‐PTL) by diffusion bonding. This novel approach does not require a flow field in the bipolar plate. When using the mesh‐PTL without PSL, the cell potential increases significantly due to mass transport losses reaching ca. 2.5 V at 2 A cm−2 and 90 °C. On the other hand, the PEMWE with the PSL/mesh‐PTL has the same cell potential but at 6 A cm−2, thus increasing substantially the operation range of the electrolyzer. Extensive physical characterization and pore network simulation demonstrate that the PSL/mesh‐PTL leads to efficient gas/water management in the PEMWE. Finally, the PSL/mesh‐PTL is validated in an industrial size PEMWE in a container operating at 90 bar H2 output pressure.

PEM Electrolysis In article number 2100630, Aldo Sau Gago and co‐workers develop novel porous transport layers for proton exchange membrane water electrolyzers, allowing operation under extreme conditions of current density, temperature, and pressure. By optimizing the water/gas transport properties of this component, a flow field in the bipolar plate becomes unnecessary. Thus, high production rates of hydrogen can be achieved efficiently, making it more economically attractive.

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For proton exchange membrane water electrolysis (PEMWE) to become competitive, the cost of stack components, such as bipolar plates (BPP), needs to be reduced. This can be achieved by using coated low-cost materials, such as copper as alternative to titanium. Herein we report on highly corrosion-resistant copper BPP coated with niobium. All investigated samples showed excellent corrosion resistance properties, with corrosion currents lower than 0.1 µA cm−2 in a simulated PEM electrolyzer environment at two different pH values. The physico-chemical properties of the Nb coatings are thoroughly characterized by scanning electron microscopy (SEM), electrochemical impedance spectroscopy (EIS), X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). A 30 µm thick Nb coating fully protects the Cu against corrosion due to the formation of a passive oxide layer on its surface, predominantly composed of Nb2O5. The thickness of the passive oxide layer determined by both EIS and XPS is in the range of 10 nm. The results reported here demonstrate the effectiveness of Nb for protecting Cu against corrosion, opening the possibility to use it for the manufacturing of BPP for PEMWE. The latter was confirmed by its successful implementation in a single cell PEMWE based on hydraulic compression technology.

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