Innovative Quality Assurance for Cell Stacks in Electrolysers and Fuel Cells

Cell stacks form the key component of modern electrolysers and fuel cells – and at the same time represent a significant cost factor in their overall systems. While these components have predominantly been manufactured using manual production processes to date, there is currently a global shift towards automated mass production on a gigawatt scale. The aim is to significantly reduce production costs while simultaneously increasing quality and reproducibility.

A key obstacle in this transformation process is the lack of efficient, imaging-based testing methods for spatially resolved quality control of cell stacks directly in the production process. Currently, electrical characteristics can only be recorded after complete commissioning in a test bench – a time-consuming and resource-intensive step.

What is missing is a practical measurement method for determining current density and conductivity distributions within electrolysis and fuel cell stacks. The goal is to enable reliable and rapid quality testing at the end of the production line – directly in production, without detours via complex test facilities.

In this project, Fraunhofer CSP is working in collaboration with DENKweit to develop a practical measurement method for determining current density and conductivity distributions within electrolysis and fuel cell stacks. The aim is to enable reliable and rapid quality testing at the end of the production line – directly in production, without the need for complex testing facilities.

Our research approaches at a glance:

• Development of an innovative measurement method for recording current density and conductivity distributions in electrolysis and fuel cell stacks – specifically for end-of-line quality control.
• Qualification of a prototype measurement setup in terms of measurement capability and defect detection accuracy – as a basis for subsequent product development in collaboration with our industry partner DENKweit.
• Technological approach: Detection of temporally and spatially variable magnetic fields in the vicinity of the cell stack, which are generated by high-frequency alternating current inside the stack.