Hydrogen at Fraunhofer 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.

Efficient Protective Coatings: The Barrier Effect of Coatings Against Hydrogen

Coatings play a key role in reducing hydrogen permeation and thus in protecting materials and components. At Fraunhofer LBF, the focus is on the independent analysis and evaluation of this barrier effect under realistic operating conditions.

• Evaluation of hydrogen permeation in different coating systems
• Investigation of material behavior under combined hydrogen and cyclic stress
• Comparison of coated and uncoated samples for quantitative assessment of the barrier effect
• Derivation of reliable performance metrics, e.g., for service life and permeation behavior

Application examples at material level

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.

Ensuring the performance of electrolytic components under extreme environmental conditions

Analysis of polymer components, e.g., seals or membranes for fuel cells and electrolysers:

• Static and dynamic
• Humidity and temperature dependence
• Coolants, acids, and alkalis
• Various loads, pressure, and temperature ranges

The long-term performance and service life of components are ensured through precise experimental investigations. At the same time, these investigations contribute to increased efficiency and safety. On this basis, a reliable design of components for hydrogen systems can be guaranteed.

Application examples at component level

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