The 5th Laser Colloquium Hydrogen 2024 (LKH2) on September 10 and 11, 2024 in Aachen brought together around 60 experts from industry, science and research. The now established conference is the ideal platform for discussing the latest developments and applications of laser technology for fuel cell and hydrogen production. The focus of the two-day event at the Fraunhofer Institute for Laser Technology ILT was on the continuous production of metallic bipolar plates, process monitoring and the functionalization of surfaces.
The presentations
The 17 presentations at this year's LKH2 discussed various aspects of the industrial production of fuel cells and the use of laser technologies along the entire process chain. They are briefly reported on below.
In his presentation, Tobias Keller from Fraunhofer ILT explained the advantages of laser radiation in the processing and structuring of bipolar plates in order to maximize the efficiency and durability of these components. The structuring and optimization of bipolar plates are decisive steps on the way to more powerful and cost-efficient fuel cells. Roll-to-roll production, in which materials can be processed more efficiently and cost-effectively, is becoming increasingly important.
Prof. Dr. Eike Hübner from the Fraunhofer Heinrich Hertz Institute HHI demonstrated how laser-induced nanostructures can significantly improve the surfaces of fuel cells, for example as nanofoams. These nanoforms have a high porosity and surface enlargement, which makes them interesting for various applications. Laser induced nano forms offer a significant surface enlargement by a factor of 3000 compared to conventional structures.
Laser-based processes as drivers for hydrogen technology
Ultra-short pulse (USP) lasers, with which such nanostructures can be produced, offer further considerable opportunities. Stoyan Stoyanov from Fraunhofer ILT explained how USP lasers can be used to realize complex cutting contours in bipolar plates (BPP), such as gas and cooling water inlets and outlets.
Dr. Steffen Berger from Schaeffler AG also focused on the laser processing of metallic BPPs with USP lasers in his presentation. They enable the precise processing of filigree structures in the µm range with minimal material change and high repeat accuracy.
Dr. Martin Müller from Forschungszentrum Jülich emphasized the importance of electrolysis in the hydrogen production process and pointed out that the key to increasing efficiency lies in improving the materials used. He explained newly developed electrode structures and their catalysts, which are used in electrolysis and in fuel cells.
The presentation by Dr. Simon Britten from Laserline showed how diode lasers can be used more efficiently and precisely for various industrial processes, particularly in electrolysis and in the production of fuel cells. With laser technology, energy savings of 20 to 30 percent in operating costs are possible in the drying process.
" The established conference is the ideal platform for discussing new developments in the hydrogen economy"
Cross-border networks for the hydrogen economy
An important part of the conference was the exchange on international cooperation, which is essential for the further development of hydrogen technology. In her presentation, Dr. Dina Barbian from the eco2050 Institute for Sustainability highlighted the need for global cooperation in order to overcome the challenges of sustainable hydrogen production. She emphasized the importance of cooperation between countries with different resources in order to make both hydrogen production and transport infrastructures more efficient.
A good example of international cooperation was presented by Robert McConville of Hysata Pty Ltd from Unanderra, Australia. He was connected live: The company says it wants to use its capillary electrolyzers to supply the world's cheapest green hydrogen in the future. This project demonstrates the importance of international cooperation in overcoming major technological challenges. Such collaborations not only promote technological innovation, but also drive the development of infrastructures for the production, transportation and storage of hydrogen worldwide.
During the lab tour, Eduard Weisser (left) demonstrated in concrete terms what he had explained in his presentation together with Dr. Yingwei Wu about extreme high-speed laser cladding (EHLA). This process can be used to provide metal surfaces with high-strength protective coatings that protect against hydrogen embrittlement and thus increase the service life and safety of components
Innovations for industrial fuel cell production
Heiko Baumann from the Fraunhofer Institute for Production Technology IPT explained the progress being made in the transportation and, above all, storage of hydrogen. Dr. Michael Rhode from the Federal Institute for Materials Research and Testing, Berlin, also spoke about the challenges involved in manufacturing electrolysers, fuel cells, storage and distribution systems. Hydrogen has very specific requirements for materials, particularly with regard to corrosion resistance and temperature changes.
Dr. Benjamin Hertweck from Hugo Kern und Liebers spoke about laser welding and punching techniques for increasing efficiency in the manufacture of fuel cells. In his presentation, Richard Steinbrecht from Lessmüller Lasertechnik in Munich emphasized the importance of continuously monitoring laser processes in order to detect errors in production at an early stage. "At the end of the day, it all comes down to the precision of the bipolar plate," emphasized Stefan Kaiser from Andritz Kaiser GmbH.
Precise and efficient laser welding techniques can improve the quality and consistency of the connections, which is particularly important for the delicate structures of the BPP. Even the smallest errors in production can lead to a significant reduction in performance. Defects such as melt accumulation along the weld seam are more common at high speeds, and can be detected and rectified at an early stage through process monitoring, Elie Haddad from Fraunhofer ILT made clear.
Laboratory for practice-oriented research and industry cooperation
Following the laboratory tours at the Fraunhofer ILT on Tuesday morning, the participants explored the HydrogenLab in the afternoon. The Laser Institute has created the conditions there to develop the fuel cell from the basics to series production. The practice-oriented environment of the HydrogenLab is designed for interdisciplinary collaboration and offers optimal conditions for public projects and industrial cooperation.
"Once again, this year's LKH2 has shown that cooperation between institutes and companies is essential for mapping the entire production and process chain in hydrogen technology," summarized Alexander Olowinsky. Laser processes, from tool technology to cutting and welding to surface functionalization, also play a decisive role, especially from an energy point of view.
