A Review on : Impact of Corrosion on Fuel Efficiency and Performance in Hydrogen and EVs

Abstract

The shift from internal combustion engine (ICE) vehicles, which depend on fossil fuels, to other power sources is essential for meeting global climate and public health goals. This paper looks at the environmental and material-specific effects of Battery Electric Vehicles (BEVs) and Hydrogen Fuel Cell Vehicles (HFCVs) compared to traditional ICE vehicles, focusing on the unique issues posed by corrosion. Although the advantages of EVs and HFCVs in cutting tailpipe emissions and greenhouse gases are well-established, the change in energy source greatly affects the corrosive environment a vehicle faces. This research first highlights the well-known environmental benefits of zero-emission vehicles over fossil-fuel vehicles, discussing lifecycle emissions and air quality improvements. The paper then explores how this transition affects vehicle lifespan and integrity by examining the corrosion mechanisms in BEVs and HFCVs versus ICE vehicles. Important differences arise regarding the types and locations of corrosion. Fossil fuel vehicles mainly suffer from rust due to road salts and the acidic byproducts of fuel combustion. In contrast, EVs and HFCVs create new corrosion pathways, such as galvanic corrosion from multi-material chassis design and the risk of corrosion in high-voltage battery and fuel cell systems. The findings show that while BEVs and HFCVs remove traditional rust issues, they introduce new and complex corrosion risks that need innovative mitigation strategies. The paper argues that recognizing and managing these new corrosion risks is crucial for ensuring the durability and long-term sustainability of the next generation of transportation. The study concludes by suggesting that ongoing progress in material science, protective coatings, and isolation techniques will be vital for unlocking the full potential of these clean energy vehicles.

Introduction

India is transitioning its transport and energy sectors toward clean mobility to achieve Net Zero emissions by 2070, driven by rising urban pollution, fuel demand, and dependence on oil imports. Electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs) are central to this shift, as vehicular emissions are a major contributor to air pollution in Indian cities. Government policies and future projections show a significant reduction in vehicle-related pollution by 2045 through electrification, hydrogen adoption, and renewable energy integration.

A major challenge affecting the long-term efficiency, cost, and reliability of both EVs and HFCVs in India is corrosion. India’s diverse climate—characterized by high humidity, coastal salinity, temperature extremes, and air pollution—accelerates material degradation. In hydrogen fuel cells, corrosion impacts critical components such as bipolar plates, catalysts, gas diffusion layers, current collectors, and hydrogen storage systems, leading to higher resistance, reduced efficiency, increased heat generation, shorter lifespan, and higher maintenance costs. EVs also face corrosion issues in battery terminals, connectors, and cooling systems, which can reduce efficiency and increase operational risks.

The paper reviews how corrosion directly lowers fuel cell efficiency, vehicle range, and durability while increasing lifecycle costs. It emphasizes the need for corrosion-resistant materials, advanced coatings, improved water and thermal management, air filtration, and infrastructure innovations tailored to Indian conditions. Addressing corrosion is essential for ensuring reliable, affordable, and sustainable clean mobility, supporting India’s National Green Hydrogen Mission, reducing emissions, and building long-term public trust in green transportation technologies.

Conclusion

Corrosion is a key factor in the future success of hydrogen fuel cell vehicles and electric mobility in India. If material degradation related to India’s climate and pollution is not addressed, the benefits of clean mobility in terms of cost and efficiency cannot be fully realized. However, progress in materials engineering, coatings, and system design can significantly improve durability. With smart investments and dedicated research and development, India can tackle corrosion issues and speed up the transition to sustainable, zero-emission mobility.

References

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Copyright

Copyright © 2025 Falguni Bhavsar, Arnav Badhan, Ayush Chitnis, Raj Wadhwani, Rudrank Suranje. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.