Development of a New Aluminizing Method for Molten Carbonate Fuel Cell Wet Seals

[+] Author and Article Information
S. Frangini

 ENEA CRE Casaccia, Hydrogen and Fuel Cells Project, Via Anguillarese 301, 00060 Rome, Italy

S. Loreti


A. Masci


J. Fuel Cell Sci. Technol 2(1), 60-64 (Jul 30, 2004) (5 pages) doi:10.1115/1.1843119 History: Received June 23, 2004; Revised July 29, 2004; Accepted July 30, 2004

A new aluminization method for molten carbonate fuel cell bipolar plate wet seals is described in this paper based on the application of the electrospark deposition (ESD) process. The molten carbonate corrosion behavior of single Al, FeAl, and a dual (FeAlAl) diffusion coating applied onto a AISI 316L steel sheet of 0.5 mm thickness is examined. FeAl-containing coatings show low-rate corrosion after exposure to a (Li+K) carbonate melt at 650 °C for 1000 h, whereas the single Al coating suffers excessive corrosion. Coatings degradation modes involve interdiffusion phenomena and transient formation of nodule iron–oxides. The dual (FeAlAl) coating exhibits the best corrosion resistance due to its higher Al surface content. Characteristics of the ESD coatings in terms of thickness, uniformity, and composition are also reported.

Copyright © 2005 by American Society of Mechanical Engineers
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Figure 1

SEM micrographs of cross sections showing the Al-diffusion coatings deposited by the electrospark process: (a) FeAl–ESD, (b) FeAl∕Al–ESD, and (c) Al–ESD coatings

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Figure 2

Vickers microhardness behavior from surface to steel substrate of the as-deposited ESD coatings

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Figure 3

XRD spectra of as-deposited ESD coatings: (a) FeAl and (b) dual FeAl∕Al coatings

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Figure 4

Plot showing the corrosion behavior of coated steel samples in molten (Li+K) carbonate at 650 °C

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Figure 5

SEM micrographs of cross sections showing the Al-diffusion coatings after 1000 corrosion testing: (a) FeAl–ESD, (b) FeAl∕Al–ESD, and (c) Al–ESD coatings

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Figure 6

SEM image of the FeAl–ESD coating showing an example of nodule development after exposure to 1000 corrosion testing



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