HyCoFC research project works on bipolar plates for fuel cells

In the HyCoFC research project, industry and research partners are working together to develop bipolar plates for durable, cost-effective and high-performance fuel cells, especially for heavy-duty applications. Participants in the project include Thyssenkrupp Steel and the Fraunhofer Institutes ILT and UMSICHT.

The aim of the project is to develop emission-free alternatives for road freight transport. The project partners hope to design a fuel cell stack that is significantly lighter than battery-electric solutions and therefore enables a higher payload for lorries. Another advantage of such fuel cell trucks over fully electric vehicles is the refuelling time, which should be significantly faster than the charging process for a battery-powered truck.

The HyCoFC project is being funded with around three million euros as part of the Energie.IN.NRW innovation competition. On the scientific side, the Fraunhofer Institute for Laser Technology ILT and the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT are involved in the project. The industrial companies involved are project coordinator Thyssenkrupp Steel as well as FEV, Schepers and Cleanlaser.

Fuel cells for heavy goods transport must be particularly robust and durable, as they are used under demanding conditions. Temperature fluctuations, mechanical loads and corrosive environments place high demands on the materials and processing of the individual components.

This is where HyCoFC comes in: The combination of a metallic carrier film (material thickness approx. 100 µm) with a conductive compound film (material thickness approx. 150 µm) combines the advantages of both materials. The large-format hybrid compound bipolar plates offer good electrical conductivity, mechanical stability and excellent corrosion resistance. These plates are designed to increase the service life of fuel cells to around 30,000 hours and reduce production costs at the same time. ‘This versatility makes the technology an ideal component for the energy transition in the mobility sector,’ explains Friederike Brackmann from the Fraunhofer Institute for Laser Technology ILT.

Thyssenkrupp Steel produces the metallic carrier film with a chrome layer to improve corrosion resistance and the bonding properties to the compound film. Fraunhofer UMSICHT specifically controls the electrical and thermal conductivity of the compound film by selecting specific materials and fine-tuning their composition. As part of the project, Fraunhofer ILT is dedicated to the further development of laser-based technologies for the production and functionalisation of hybrid compound bipolar plates.

In the Fraunhofer ILT’s in-house Hydrogen Lab, researchers will find a comprehensively equipped infrastructure that is specifically geared towards the practical development and optimisation of hydrogen technologies. Modern laser technology testing facilities and test benches have been set up on an area of 300 square metres, making it possible to test and further develop individual production steps as well as complete process chains and specific industrial applications under realistic conditions.

ILT employee Friederike Brackmann tests here, for example, how the bipolar plates can be joined in a hydrogen-tight and reproducible manner using laser welding. Her colleague Tobias Erdmann is investigating how the contact resistance between the bipolar plate and the gas transport layer can be optimised. “We expose the conductive graphite filler material in the contact area with the gas transport layer,” explains the researcher. “Unlike mechanical grinding processes, ultrashort pulsed laser radiation can selectively remove the plastic without damaging the filler material.”

According to the Fraunhofer ILT, the hybrid compound bipolar plates offer the potential to significantly increase the service life of fuel cells and expand their range of applications. From heavy-duty vehicles to maritime applications and stationary systems, the project opens up a wide range of perspectives for a climate-friendly energy supply.

“A particular focus at HyCoFC is on developing processes that enable economically scalable and cost-efficient production in large quantities,” says Tobias Erdmann. “We are focusing on the roll-to-roll process, which ensures continuous and high-quality processing of the materials. We want to implement and test this next.”

ilt.fraunhofer.de (press release), umsicht.fraunhofer.de (project page)

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