Hydrogen at Fraunhofer LBF

Reliability of materials, components and systems for the hydrogen economy

 

Hydrogen is an energy carrier that has a positive impact on the energy transition and counteracts climate change.

At Fraunhofer LBF, interdisciplinary teams of experts are developing new processes and methods for evaluating and optimizing the reliability of materials, components, and systems for the hydrogen economy.

​​To this end, we design new test systems, from conceptualization and design to construction, commissioning, and application. The projects cover the topics of hydrogen production, storage, transport, and use. We offer our services at all levels of the hydrogen economy—materials, components, and systems.

 at material-level

we examine metals, plastics, and composites under realistic conditions. Samples are analyzed cyclically or statically under pressurized hydrogen at appropriate temperatures. Other media such as methanol or ammonia can also be used

at component-level

we examine membranes, pipes, and stacks, for example. These can be analyzed in our custom-developed test facilities with regard to their service life and reliability.

at system-level

we conduct experimental and numerical testing.

Fuel cells can be tested in our multi-axial MAST shake table under multi-axial vibration loads such as those encountered during vehicle operation. We develop methods that allow crack formation and progression in an H2 tank to be measured in a spatially resolved manner. Such applications make it possible to determine whether a tank is still intact after a car accident.

Our offer – your benefits

Materials of the H2 economy

 

 

Components of the H2 economy

Systems of the H2 economy

Contact

Dr. Saskia Biehl

Strategic Managment

Fraunhofer Institute for Strucktural Durability and System Reliabiliy LBF

Materials for the hydrogen economy

We test metals, plastics, and composites under realistic conditions.

Sensor

With knowledge of material stresses and the recording of physical-technical relationships such as damage mechanisms and material stresses, you can design your products in a targeted manner and make optimum use of materials.

By identifying and eliminating weak points, you can recognize optimization potential and reduce your product costs.

Acoustic emission (AE) measurements on material samples

With real-time detection and analysis of damage processes, you can

  • avoid failures and repairs
  • We support you in the development of more robust and durable materials.

Test bench development & realistic testing

  • Application-oriented evaluation of strength, deformation, and fatigue behavior under complex stresses in liquid and gaseous media
  • Physical and chemical characterization of plastics for hydrogen applications
  • Quick test for metallic samples against hydrogen
  • Sorption of hydrogen
  • Service life assessment under the influence of corrosive environments
  • Substitution options for PFAS in specific hydrogen applications

With our methods and test facilities, you are in a position to make the optimal material selection or develop the right material for cost-efficient and sustainable hydrogen systems. We support you in significantly improving the performance of plastics and metals for hydrogen systems and increasing the reliability of (lightweight) structures.

Application examples at material level

 

Plastics in hydrogen applications

Testing techniques and design methods

 

 

HydroTransSeal

Elastomer seals for H2 transport

Components of the hydrogen economy

Experimental investigation of components

  • Single cell test under vibration loads
  • Characterization and long-term testing

Experimental and numerical vibration analysis

  • Determination of preload forces of stacks in operation
  • Experimental vibration analysis of, for example, fuel cell stacks and cells
  • Simulation and modeling of behavior under various conditions

Our test results can be used to optimize the design and structure of fuel cell stacks and cells. Our findings and technical consulting help you improve efficiency and reliability.

Finite element structural simulation of components

  • Development of digital twins for metallic and polymer components
  • Numerical mapping and evaluation
    • Interactions between media, aging effects, and mechanical loads
    • Service life of e.g. welded joints under various loads
  • Determination of characteristic values and development of material models
  • Development of design methods for safe plastic components

Our expertise and precise design methods enable us to increase efficiency in the area of design and ensure the long-term performance and safety of your components.

  • Investigation of plastic components such as seals and membranes for fuel cells and electrolysers

The specific experimental test environments provide comprehensive results to ensure the performance of electrolytic components under extreme environmental conditions.

Application examples at component level

 

Cyclic stress resistance under hydrogen

Reduction of the fatigue strength due to the influence of hydrogen

 

»Hy2Design«

Sealing materials for transport

Hydrogen economy systems

Multiphysical evaluation of fuel cells

  • Load data acquisition and measurement campaigns
  • Sensor instrumentation and data evaluation
  • Vibration stress tests using a multiaxial vibration table (MAST) and shakers

Based on our detailed data acquisition and analysis, you will be able to make well-founded decisions. The realistic analyses provide information on, for example, the aging behavior of fuel cell systems.

System identification and numerical simulation

  • Evaluation of the diverse effects of vibrations depending on various factors, such as:
    • Position in the vehicle
    • Structure and tensioning of the cell stack
    • Connection of BoP components

Analyzing and understanding the effects of vibrations early in the development process saves time and money.

Tank systems

  • Analysis of H2 pressure tank: expansion, material stress, pressure tests, impact
  • Reliable installation in the vehicle during pressure cycles and crashes
  • Condition monitoring of hydrogen tanks
    • Specific generation and detection of fiber breaks, matrix breaks, and delamination in the tank material during service life tests and operation

Based on the results, we develop algorithms for evaluating service life consumption.

We advise you on reliable tank mounting in the vehicle and service life monitoring. We develop specific mobile or stationary monitoring systems for your tank systems.

In the event of a traffic accident, we are the right contact for assessing tank safety.

Probabilistic Failure Mode and Effect Analysis (FMEA)

  • Reliability and safety analyses
    • Qualitative methodical error analyses
    • Probabilistic system evaluation
  • Sensitivity analyses to determine the most significant influencing factors and risk assessment
  • Efficient calculation models for quantifying uncertainty

These methods and analyses form the basis for our technical consulting on the reliability and safety of your systems:

  • Failure probabilities at system and subsystem level
  • Further considerations, e.g., functional safety

Application examples at system level

 

multiPEM

Fuel cell stacking under multiphysical-chemical stress in commercial vehicles

 

HyMon: Smart tanks for hydrogen vehicles

Sensor-based condition monitoring of automotive hydrogen pressure vessels