Due
to oxygen- or hydrogen-rich environments, metallic bipolar
plates in proton exchange membrane (PEM) fuel cells (FCs) are extremely
prone to corrosion. In this work, the corrosion behavior of pure aluminum
(Al) and its correlation between the simulated and real environments
in the PEM FC were investigated, where the word “real”
means the recovered solutions that were collected from the cathode
and anode of the PEM FC during the 500 h of single-cell power generation
test. The single-cell power generation test was performed for 500
h using graphite, bare Al, and TiN-SBR-coated Al as the reaction gas
isolating plates for use as bipolar plates in the PEM FC. The corrosion
rate of pure Al was calculated after immersion in different solutions,
such as distilled water, sulfate ions, fluoride ions, and their combined
solutions. The electrochemical behavior of pure Al was evaluated by
polarization tests, which showed that the higher corrosion resistance
was found in the solutions with higher pHs. Corrosion morphology,
surface roughness, structures of corrosion products, and elemental
compositions in simulated and real environments were measured and
examined. The results revealed that higher and lower amounts of oxide
layers as corrosion products were found for the presence of fluoride
and sulfate ions, respectively, in the tested solutions. In addition,
the study of the cathode and anode sides of used bipolar plates before
and after the single-cell power generation test reports that the light
and whitish corrosion products were captured on the anode side, and
interestingly, almost no corrosion layers were seen on the cathode
side of the bipolar plates after PEM FC operation. Thus, it was suggested
that Al can be considered one of the most suitable materials for use
as bipolar plates in a PEM FC, where the higher voltage and improved
corrosion resistance were found using TiN-SBR-coated Al plates.