Key Initiatives This Happens When Hydrogen Technology Meets Additive Manufacturing

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The Chair of Digital Additive Production (DAP) at RWTH Aachen (Germany), together with partners, is developing new additive manufacturing opportunities along the entire hydrogen value chain...

Hydrogen is known as one of the key energy carriers for achieving successful decarbonization of energy-intensive processes. However, the challenges along its value chain are complex, ranging from energy-intensive production to demanding transportation and efficient use in high-temperature processes, as explained by the DAP. But this is precisely where research is now focusing, with the use of digital tools and additive manufacturing methods to upgrade existing infrastructures, enable new applications, and accelerate industrial production processes. The research discussed below is part of the “Clusters4Future Hydrogen” and “SupplHyInno Rhineland” initiatives. In the long term, the insights gained from this are intended to contribute to the development of industrially scalable cell architectures, making it possible to transfer the knowledge to related applications such as fuel cells. The project is funded by the Federal Ministry for Research, Technology, and Space. Let’s take a closer look at what is specifically meant when it comes to hydrogen production...

Powder Bed-Based Laser Melting Improves Electrolyzers

Hydrogen is produced in electrolyzers by splitting water into hydrogen and oxygen using electrical energy. However, the industrial scalability of these systems is one of the key challenges. The DAP developments therefore focus on porous transport layers (PTLs), which ensure material transport, conduct electrical charge carriers, and stabilize the cell architecture in PEM electrolyzer cells (PEM = Proton Exchange Membrane Electrolyzer). At DAP, customized PTL geometries are now being created using rapid prototyping. This is achieved through powder bed-based laser melting (PBF-LB/M) and with the help of corrosion-resistant functional coatings applied using the aerosol jet process, it is further explained. The goal is to develop robust PTL designs for mass production in a short time, while reducing the use of critical raw materials (such as iridium and platinum). But there are even more challenges that can be tackled with 3D printing...

Coatings Solve the Problem of Hydrogen Diffusion

Transporting hydrogen is not entirely straightforward either. As the smallest molecule in the periodic table, hydrogen diffuses through conventional steel pipes and also causes the unfavorable phenomenon of hydrogen embrittlement. To retrofit existing networks accordingly, DAP relies on an internal coating using High Speed Directed Energy Deposition (HS-DED). This involves applying a metallic protective layer to the inner wall of the pipes to block hydrogen molecules and extend the lifespan of the infrastructure. Along with the Institute for Textile Technology (ITA), DAP is also developing hybrid pipe systems made of fiber-reinforced plastic (FRP or composite material) combined with a metallic coating. Looking ahead, the manufacturing processes are intended to be automated and directly scalable on-site. According to the researchers, this novel and innovative combination of metal and plastic is lightweight, corrosion-resistant, and highly durable. And there’s still more to improve...

A Special Burner Kit is Intended to Help Reduce Emissions

Finally, the use of hydrogen in energy-intensive industries also requires new concepts, as the researchers in Aachen further explain. For this reason, DAP is developing industrial burners for flexible operation with natural gas-hydrogen mixtures. To this end, flame stability, emission behavior, and heat distribution are being optimized. Digital twins and predictive simulation models serve as the basis for inverse design and create a digital testing environment. Within this framework, flow, reaction, and manufacturing conditions are simulated. Subsequently, highly functional prototypes with high thermal resistance are produced via additive manufacturing using PBF-LB/M with copper-based materials. The aim is to pave the way for a modular burner kit for industrial applications, helping to reduce CO₂ emissions in the process.

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