Characterization of Materials and Components for Membrane Electrolyzers

High efficiency and durability of electrolysers are essential for the ramp-up of the hydrogen economy and the achievement of climate targets.

In our laboratories, we characterize all main cell components and materials, in particular membrane electrode assemblies (MEA) and porous transport layers (PTL) for PEM and AEM water electrolysis. Our focus here is on performance and aging behavior as a function of relevant operating conditions such as current profile, temperature, and pressure. We use a variety of state-of-the-art in-situ and ex-situ measurement methods to gain comprehensive insights and understanding into the physical-electrochemical processes during operation and the degradation behavior of electrolysis cells and stacks and its components.

We offer a unique combination of excellent research infrastructure, long lasting in-depth electrochemical knowledge, and broad industry-relevant application expertise to meet the requirements of our customers and project partners. 

 

Your Benefits:

Precisely tailored: Thanks to our many years of experience in the in situ and ex situ characterization of electrolysis components and materials, we can adapt our laboratory hardware and components, such as membrane electrode assemblies and porous transport layers, to precisely suit the respective characterization task and to answer even your most complex R&D questions.

Innovative: Our state-of-the-art electrochemical measurement methods show you optimization potential for the further development of your materials and components.

Reliable: Thanks to our proprietary, fully automated test benches, variable measurement and characterization protocols, and automated evaluation, you receive measurements with a high degree of reproducibility and comparability.

Well-founded: Our characterization supports your material and component selection with data, providing an important basis for investment decisions.

In-Situ Screening of Membrane Electrode Assemblies and Cell Components

4 cm² electrolysis cell developed at Fraunhofer ISE for rapid screening of membrane electrode assemblies.
© Fraunhofer ISE / Foto: Joscha Feuerstein
4 cm² electrolysis cell developed at Fraunhofer ISE for rapid screening of membrane electrode assemblies.

We perform in-situ characterizations of membrane electrode assemblies (MEA) for PEM and AEM water electrolysis using 4 cm² laboratory cells. We have access to a diverse portfolio of 4 cm² test cells developed in-house, which have been optimized for various application and research tasks. The easy handling of the test cells in combination with our self-developed, fully automated parallel test benches for pressureless operation enables us to quickly screen a large number of different membrane electrode assemblies. The knowledge gained in this way can be directly transferred to the MEA production research. In addition, we gain important insights into the optimization of cell components and configurations that can be transferred to the design and characterization of larger cell formats and pressure operation.

The established cell design also allows rapid adaptation to other cell components such as porous transport layers and coatings for bipolar plates. This means that large amounts of reliable and reproducible data for individual components can be generated in fast and cost-effective screening tests.

Comprehensive Electrochemical In-Situ Characterization of Membrane Electrode Assemblies and Cell Components

25 cm² electrolysis cell developed at Fraunhofer ISE with reference electrode for in-situ characterization of components up to 30 bar.
© Fraunhofer ISE / Foto: Joscha Feuerstein
25 cm² electrolysis cell developed at Fraunhofer ISE with reference electrode for in-situ characterization of components up to 30 bar.

For extensive and complex in-situ characterizations in PEM and AEM water electrolysis, we rely on our 25 cm² laboratory cells. With the help of pressure-resistant single-cell test benches, we can apply large parameter sets with differential pressures up to 50 bar, temperatures up to 120 °C, and electrochemical stress protocols up to 1000 A in a fully automated manner. Our self-developed hardware offers you great flexibility in terms of cell design and operating conditions.

Electrochemical analysis methods such as cyclovoltammetry and electrochemical impedance spectroscopy are used as standard on all test stands. In addition, we offer various other methods such as product gas analysis (H2 in O2, O2 in H2) using a thermal conductivity detector and gas chromatography, as well as water analysis using ICP mass spectroscopy and ion chromatography.

In addition, we have many years of expertise and the appropriate hardware for spatially resolved measurement of PEM electrolysis cells using a 60 cm² along-the-channel laboratory cell.

Fully Automated In-Situ Characterization of PEM Electrolysis Stacks

Self-developed, fully automated PEM electrolysis stack test bench for characterizing short stacks with up to 1500 A current.
© Fraunhofer ISE / Foto: Joscha Feuerstein
Self-developed, fully automated PEM electrolysis stack test bench for characterizing short stacks with up to 1500 A current.

We offer extensive and comprehensive in-situ characterization of short stacks for PEM water electrolysis. Based on our short stack test bench developed at the institute, we can investigate large parameter sets such as differential pressures, temperatures, and electrochemical aging protocols in a fully automated and flexible manner. With our hardware, currents of up to 1500 A, voltages of up to 25 V, pressures of up to 50 bar, and operating temperatures of up to 80 °C can be achieved. The internal cooling capacity is 15 kW.

To complement the electrochemical characterization, we offer various other methods such as product gas analysis (H2 in O2, O2 in H2) using a thermal conductivity detector and gas chromatography, as well as water analysis using ICP mass spectroscopy and ion chromatography.

Extensive Ex-Situ Characterization of Materials and Components

In-plane and through-plane characterization of two-phase flows in PEM electrolyzers.
© Fraunhofer ISE
In-plane and through-plane characterization of two-phase flows in PEM electrolyzers.

In addition to our detailed electrochemical in-situ characterization in full-cell electrolysis systems, we offer comprehensive services for ex-situ characterization of materials and components. One focus is on the characterization of porous transport layers (PTL) for water electrolysis. We offer various fluidic investigations, such as porosimetry and in-plane and through-plane permeability measurements in single-phase and two-phase flows. This enables us to determine specific characteristics of porous materials, such as pressure loss and flow regime, while simultaneously flowing gas and liquid through them. In addition, we have a wide range of other measurement methods at our disposal to precisely determine additional properties of the materials and components. These include, among others:

  • Scanning electron microscopy (FIB-SEM, SEM-EDX)
  • Micro-computed tomography (µCT)
  • Liquid analysis (ICP-MS; ion chromatography)
  • Optical microscopy (CLSM)
  • X-ray fluorescence analysis and spectroscopy (XRF, XRD, NAP-XPS)
  • Corrosion and contact resistance measurements

R&D Infrastructure

Our research and development activities make use of the excellent infrastructure at Fraunhofer ISE:

 

Elektrolysis Lab

We characterize and analyse electrolysis materials, cells and entire stacks. We support the upscaling of electrolyzers using state-of-the-art components and production research for the membrane electrode assembly.

 

Production Research Lab for Membrane Electrode Assemblies

Our production research considers the entire value chain, from catalyst powder to a 7-layer MEA, including quality control. 

Research Projects on the Topic Characterization of Materials and Components for Membrane Electrolyzers

 

SpinCat

Spin-polarized Catalysts for Energy-Efficient AEM Water Electrolysis

 

StacIE

Stack Scale up – Industrialization of PEM Electrolysis

 

PEP.IN

H2Giga Project for the Industrialisation of PEM Electrolysis Production and Innovative Stack Component Development

 

CleanHyPro

Open Innovation Test Bed for Electrolysis Materials for Clean Hydrogen Production

More Information on this Topic

Research Topic

Electrolysis and Hydrogen Infrastructure

Business Area

Hydrogen Technologies