Swiss and French Researchers Develop Industrial-Scale Corrosion-Resistant Components for Hydrogen Electrolysis

Empa researcher Konstantin Egorov coats stainless steel components with corrosion-resistant titanium oxide to make the production of green hydrogen more cost-effective. Image: Empa

(IN BRIEF) Researchers at Empa and partner institutions in France are developing new corrosion-resistant materials designed to lower the cost of green hydrogen production through proton-exchange membrane water electrolysis. By replacing expensive platinum coatings and titanium components with steel and conductive titanium oxide coatings, the team hopes to make electrolysers more affordable, durable, and easier to manufacture at industrial scale. Early tests have shown promising corrosion resistance, and the project could play an important role in accelerating the commercialization of sustainable hydrogen technologies.

(PRESS RELEASE) DÜBENDORF, 20-May-2026 — /EuropaWire/ — Green hydrogen production could become significantly more affordable thanks to new materials being developed by researchers at Empa and their international collaborators. The project focuses on improving proton-exchange membrane water electrolysis (PEMWE), a technology widely regarded as one of the most promising methods for producing hydrogen using renewable energy sources.

Hydrogen generated through electrolysis has long been viewed as a key component of the global energy transition because it can store renewable energy and replace fossil fuels in industrial and transport applications. Unlike hydrogen derived from natural gas, green hydrogen produces no greenhouse gas emissions during its production cycle. However, the high cost of electrolysis remains a major obstacle to broader commercial adoption.

To address this challenge, researchers from Empa’s Materials for Energy Conversion laboratory are collaborating with the French Corrosion Institute and LEMTA in a project supported by the Swiss National Science Foundation and the Agence Nationale de la Recherche. Their goal is to develop more economical alternatives for critical electrolyser components that currently rely on expensive titanium and platinum materials.

The bipolar plate shows no signs of corrosion. Image: Empa

Inside PEMWE systems, highly corrosive conditions make conventional steel unsuitable because it quickly deteriorates when exposed to acidic environments. As a result, manufacturers rely heavily on titanium components coated with platinum to prevent oxidation and maintain efficiency. These materials contribute substantially to the overall cost of green hydrogen production.

Empa researcher Konstantin Egorov and his team are working on replacing these costly coatings with a specialized titanium oxide material known as highly crystalline oxygen-deficient rutile. The material combines strong conductivity with high resistance to corrosion due to its unique crystalline structure and oxygen-deficient properties.

The research team is also replacing titanium carrier materials with steel, which is less expensive and easier to manufacture into advanced designs that can improve electrolyser performance. To apply the protective titanium oxide layer, the scientists are using physical vapor deposition (PVD), a coating process already widely adopted in industrial manufacturing, helping ensure the technology can be scaled for commercial use.

Initial testing has produced promising results. Researchers successfully coated the PEMWE electrolyser’s bipolar plate with the new titanium oxide material, and corrosion tests have shown strong durability under demanding operating conditions. The next phase of the project will focus on coating porous transport layers, a more technically challenging task because the coating must protect the material without blocking its microscopic pores.

The project is scheduled to continue through 2026, with researchers aiming to attract industrial partners to help advance the technology toward large-scale commercialization. If successful, the innovation could help reduce the cost of green hydrogen production and support wider adoption of hydrogen-based energy systems worldwide.

Further information
Dr. Konstantin Egorov
Empa, Materials for Energy Conversion
Phone +41 58 765 65 19
konstantin.egorov@empa.ch

Dr. Meike Heinz
Empa, Materials for Energy Conversion
Phone +41 58 765 65 42
meike.heinz@empa.ch

Editor / Media Contact
Anna Ettlin
Communications
Phone +41 58 765 47 33
redaktion@empa.ch

SOURCE: EMPA