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<p>Metallic bipolar plates in proton exchange membrane fuel cells (PEMFCs) offer advantages such as cost efficiency, mechanical strength, and the ability to accommodate complex geometries, improving the power-to-volume ratio. However, their susceptibility to corrosion poses a significant challenge, impacting durability and long-term performance. Protective coatings can mitigate these issues, but further advancements are required for enhanced thermal and mechanical stability. This study presents a hybrid graphene nanoplatelet (GNP)–platinum (Pt)–alumina (Al<sub>2</sub>O<sub>3</sub>) nanocomposite coating, developed using nanofluid flow boiling, to improve corrosion resistance and heat transfer performance. GNP–Pt nanocomposites were synthesized via acid treatment and platinum deposition, followed by the preparation of GNP–Pt–Al<sub>2</sub>O<sub>3</sub>/water hybrid nanofluids. The thermophysical properties of these nanofluids, including viscosity, thermal conductivity, and boiling heat transfer characteristics, were systematically analyzed. Flow boiling experiments on heated copper surfaces achieved a 219% improvement in critical heat flux (CHF) and a 330% enhancement in the heat transfer coefficient (HTC) relative to uncoated surfaces. The GNP–Pt–Al<sub>2</sub>O<sub>3</sub> nanocoated surfaces exhibited boiling characteristics similar to those of equivalent nanofluids on bare surfaces, confirming their effectiveness in improving heat transfer. Additionally, moderate nanofluid concentrations enhanced surface roughness, wettability, and capillary action, increasing the effective heat transfer area and optimizing bubble dynamics. The synergistic properties of GNP (high thermal conductivity and mechanical strength), Pt (corrosion resistance), and Al<sub>2</sub>O<sub>3</sub> (surface hardness and durability) significantly enhance heat dissipation, structural integrity, and corrosion protection. This approach provides a scalable and cost-effective solution for PEMFCs and microelectronics cooling, addressing key challenges in thermal management, system reliability, and longevity.</p>

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Advanced hybrid GNP–Pt–Al2O3 nanocomposite coatings for enhanced thermal management and corrosion resistance via nanofluid flow boiling

  • 期刊论文

  • 发表日期：

    2025年5月22日

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  • Sanjay Kumar Gupta,
  • Md Atiqur Rahman,
  • Rahul Dev Misra

摘要

Metallic bipolar plates in proton exchange membrane fuel cells (PEMFCs) offer advantages such as cost efficiency, mechanical strength, and the ability to accommodate complex geometries, improving the power-to-volume ratio. However, their susceptibility to corrosion poses a significant challenge, impacting durability and long-term performance. Protective coatings can mitigate these issues, but further advancements are required for enhanced thermal and mechanical stability. This study presents a hybrid graphene nanoplatelet (GNP)–platinum (Pt)–alumina (Al2O3) nanocomposite coating, developed using nanofluid flow boiling, to improve corrosion resistance and heat transfer performance. GNP–Pt nanocomposites were synthesized via acid treatment and platinum deposition, followed by the preparation of GNP–Pt–Al2O3/water hybrid nanofluids. The thermophysical properties of these nanofluids, including viscosity, thermal conductivity, and boiling heat transfer characteristics, were systematically analyzed. Flow boiling experiments on heated copper surfaces achieved a 219% improvement in critical heat flux (CHF) and a 330% enhancement in the heat transfer coefficient (HTC) relative to uncoated surfaces. The GNP–Pt–Al2O3 nanocoated surfaces exhibited boiling characteristics similar to those of equivalent nanofluids on bare surfaces, confirming their effectiveness in improving heat transfer. Additionally, moderate nanofluid concentrations enhanced surface roughness, wettability, and capillary action, increasing the effective heat transfer area and optimizing bubble dynamics. The synergistic properties of GNP (high thermal conductivity and mechanical strength), Pt (corrosion resistance), and Al2O3 (surface hardness and durability) significantly enhance heat dissipation, structural integrity, and corrosion protection. This approach provides a scalable and cost-effective solution for PEMFCs and microelectronics cooling, addressing key challenges in thermal management, system reliability, and longevity.