Effect of surface roughness on contact resistance and electrochemical corrosion behavior of 446 stainless steel in simulated anode environments for proton exchange membrane fuel cell

The effect of surface roughness on the interfacial contact resistance (ICR) and the corrosion behavior of 446 stainless steel in simulated anode environments for proton exchange membrane fuel cell (PEMFC) (i.e., 0.5 mol L−1 H2SO4 + 2 ppm F− and 5 × 10−4 mol L−1 H2SO4 + 0.1 ppm F− bubbled with hydrogen gas at 80 °C) was investigated by means of atomic force microscopy, potentiodynamic polarization, electrochemical impedance spectroscopy and ICR test. The surface roughness (Ra) produced by mechanical grinding increases noticeably with the decrease of sandpaper grit size from 1000# to 240#. 446 stainless steel shows the active state under free corrosion conditions in the two test solutions and the passive state at the typical anode working potential of PEMFC after the activation-passivation transition. The corrosion resistance decreases with the increase of roughness in both solutions. The corrosion product films formed in the solution with lower acidity are more protective, leading to the appearance of the diffusion process. The enlargement of surface roughness results in the gradual reduction of ICR, but the acceleration of active and passive dissolutions.