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Energies
Volume 18
Issue 13
10.3390/en18133317
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Review

Degradation and Corrosion of Metal Components in High-Temperature Fuel Cells and Electrolyzers: Review of Protective Approaches

by
Pavel Shuhayeu
1,
Olaf Dybiński
1,*,
Karolina Majewska
1,
Aliaksandr Martsinchyk
1,
Monika Łazor
2,
Katsiaryna Martsinchyk
1,
Arkadiusz Szczęśniak
1 and
Jarosław Milewski
1
1
Faculty of Power and Aeronautical Engineering, Warsaw University of Technology, 21/25 Nowowiejska Street, 00-665 Warsaw, Poland
2
Faculty of Chemistry, Warsaw University of Technology, Noakowskiego 3, 00-664 Warsaw, Poland
*
Author to whom correspondence should be addressed.
Energies 2025, 18(13), 3317; https://doi.org/10.3390/en18133317
Submission received: 13 May 2025 / Revised: 4 June 2025 / Accepted: 19 June 2025 / Published: 24 June 2025
(This article belongs to the Special Issue Advances in Electrochemical Power Sources: Systems and Applications)
Versions Notes

Abstract

High-temperature fuel cells and electrolyzers, particularly molten carbonate fuel cells (MCFCs) and Molten Carbonate Electrolyzers (MCEs), are expected to play a critical role in clean power generation, hydrogen production, and integrated CO2 separation. Unfortunately, despite their potential, these technologies have not yet reached full commercialization. The main reason for this is material degradation. In particular, the corrosion of metallic components continues to be a leading cause of performance loss and system failure. This review provides a comprehensive assessment of degradation mechanisms in MCFC and MCE systems. It examines key metallic components, such as current collectors and bipolar plates, focusing on the performance of commonly used materials, including stainless steels and advanced alloys, under prolonged exposure to corrosive environments. To address degradation issues, this review evaluates current mitigation strategies and discusses material selection, protective coatings application, and the optimization of operational parameters. Advances in alloy development, coatings, surface treatments, and process controls have been compared in terms of effectiveness, scalability, and long-term stability. The review concludes with a synthesis of current best practices and future directions, emphasizing the need for integrated, multi-functional solutions to achieve the lifetimes required for full commercialization. By linking materials science, electrochemistry, and systems engineering, this review offers directions for the development of corrosion-resistant MCFC and MCE technologies in support of a hydrogen-based, carbon-neutral energy future.
Keywords: high-temperature fuel cells; molten carbonate fuel cells; degradation; corrosion high-temperature fuel cells; molten carbonate fuel cells; degradation; corrosion

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MDPI and ACS Style

Shuhayeu, P.; Dybiński, O.; Majewska, K.; Martsinchyk, A.; Łazor, M.; Martsinchyk, K.; Szczęśniak, A.; Milewski, J. Degradation and Corrosion of Metal Components in High-Temperature Fuel Cells and Electrolyzers: Review of Protective Approaches. Energies 2025, 18, 3317. https://doi.org/10.3390/en18133317

AMA Style

Shuhayeu P, Dybiński O, Majewska K, Martsinchyk A, Łazor M, Martsinchyk K, Szczęśniak A, Milewski J. Degradation and Corrosion of Metal Components in High-Temperature Fuel Cells and Electrolyzers: Review of Protective Approaches. Energies. 2025; 18(13):3317. https://doi.org/10.3390/en18133317

Chicago/Turabian Style

Shuhayeu, Pavel, Olaf Dybiński, Karolina Majewska, Aliaksandr Martsinchyk, Monika Łazor, Katsiaryna Martsinchyk, Arkadiusz Szczęśniak, and Jarosław Milewski. 2025. "Degradation and Corrosion of Metal Components in High-Temperature Fuel Cells and Electrolyzers: Review of Protective Approaches" Energies 18, no. 13: 3317. https://doi.org/10.3390/en18133317

APA Style

Shuhayeu, P., Dybiński, O., Majewska, K., Martsinchyk, A., Łazor, M., Martsinchyk, K., Szczęśniak, A., & Milewski, J. (2025). Degradation and Corrosion of Metal Components in High-Temperature Fuel Cells and Electrolyzers: Review of Protective Approaches. Energies, 18(13), 3317. https://doi.org/10.3390/en18133317

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