Industrial-Scale MEA Production Processes For PEM Water Electrolysis And Fuel Cells

PEM electrolysis for hydrogen production from renewable energy sources, as well as PEM fuel cells as electric powertrains for heavy-duty vehicles, buses, trains, ships, and even airplanes are crucial technologies for the climate transition in Germany, Europe, and the world. In the “TIRAMISU” (Thorough International Research and Analysis of Machinery Influenced effects in Scaling Up production processes for PEM electrolysis and fuel cells) project, Fraunhofer ISE is investigating industry-relevant production processes for manufacturing membrane electrode assemblies (MEAs) for PEM water electrolysis and fuel cells using a unique roll-to-roll research platform. The focus is on the effects of process technologies and parameters on the microstructures of the produces samples and the resulting performance and aging characteristics. This addresses the central question of how the process parameters of industrial mass production influence the quality of the MEA.

Initial Situation

MEA production today generally takes place using semi-automated processes. However, these differ from the industrial processes that will be required in the future, which are designed for high throughput with minimal scrap. Furthermore, manufacturing processes at production companies are treated as strictly confidential, meaning that the industrialization efforts of individual companies yield virtually no learning effects for the industry as a whole. Through its unique production research using industry-standard equipment, “TIRAMISU” provides broad, unbiased access to the current state of the art—particularly for German and European industry.

Objective

Using fundamental scientific methods, the project aims to examine production processes that could form the basis for the future industrial manufacture of membrane electrode assemblies for electrolysis and fuel cells. In doing so, the interrelationships between process technologies within the process chain–from catalyst ink mixing through coating, drying, and, if applicable, decal film transfer, all the way to MEA fabrication–are investigated with regard to the microstructures produced and the resulting performance and aging characteristics.

Approach

“TIRAMISU” examines the interrelationships between process, the microstructures produced, and the resulting operational behavior (performance and aging) in the industrial roll-to-roll (R2R) manufacturing of membrane electrode assemblies. To this end, industrial manufacturing facilities–unique in the field of global electrolysis and fuel cell research–are used for mixing catalyst inks, catalyst coating, drying, transfer, and converting (5-layer MEA production).

By varying the process technologies and process parameters, the effects on the microstructures formed in the catalyst-coated membranes (CCMs) and 5-layer MEAs (CCMs with subgaskets laminated on both sides) are evaluated. Subsequently, the fabricated MEAs will be characterized in situ to assess their operational and degradation behavior in electrolyzers and fuel cells. The experimental data generated will be used to train neural network models for machine learning (ML). These artificial intelligence methods will be used to gain insights into multiphysical processes whose experimental investigation is too complex and costly.

The “TIRAMISU” project is funded by the Federal Ministry of Research, Technology and Space (BMFTR).