Fuel Cell Stacks under Multiphysical-Chemical Stress in Commercial Vehicles

Testing and Understanding Fuel Cell Stacks under Highly Complex, Multiphysical Stress

One of the greatest challenges for the economy and society in the 21st century is the implementation of extended measures for climate protection and CO2 reduction. An important contribution to this is electromobility, which is increasingly focusing on the electrification of trucks and commercial vehicles (CVs). The provision of electrical energy with hydrogen fuel cells offers a promising solution. For this purpose, so-called low-temperature polymer electrolyte membrane fuel cells (NT-PEM-FC) are combined in a stack. The mobile use of these FC stacks in CVs is subject to highly complex, multiphysical (mechanical, thermal, and electrical) and chemical stresses. Little is known about the superimposed influences of these stresses on the safety and system reliability of the FC stack. Since FC-based drives in CVs are currently only available as prototypes, but the required operating life is more than three times longer than that of passenger cars, the reliable and efficient design of these system solutions plays an essential role in their rapid and sustainably successful transfer to widespread application. However, this requires extended and new analysis and evaluation procedures that enable cost- and time-efficient as well as safe and reliable design of FC stacks for CVs.

Development of Analysis, Evaluation, and Testing Procedures for All Stages of the Fuel Cell Value Chain

 In the multiPEM project, analysis, evaluation, and testing procedures are being developed to manage the complex stress state of NT-PEM-FC in CVs, thereby improving their safety and reliability. For the first time, the effects of superimposed multiphysical-chemical stresses are being considered and transferred into methods relevant for application.

Key areas include:

• Development of test procedures and conditions to investigate the effects of vibrations and pollutants
• Development of methods for non-destructive condition assessment using high-energy computed tomography and magnetic field sensors
• Microstructural analysis and methodological system reliability assessment