Green Hydrogen for the Energy Transition

Hydrogen technology will play a key role in increasing economic sovereignty and achieving climate protection goals in Germany and Europe. Hydrogen is an environmentally friendly, safe, and powerful energy and material carrier that can be produced efficiently and sustainably. It enables sector coupling between electricity, heat, mobility, and industry, and is an essential material carrier for industrial processes. However, to establish a functional and economic hydrogen economy, there is still a need for research and infrastructure development, such as in the areas of cost-effective electrolysis processes, robust materials, storage solutions with high performance and energy density, and hydrogen transport.

The topic of hydrogen has been intensively researched at Fraunhofer IFAM for over 20 years. This makes the institute an integral part of the hydrogen community and supports the industry with its materials and manufacturing expertise along the hydrogen value chain – from fundamental research and the development of innovative materials and processes to practical testing and industrial implementation. Our research focuses on:

• Sustainable hydrogen production
• Transport and storage of hydrogen
• Use/applications of hydrogen
• Material and process innovations in the field of hydrogen
  

The research work focuses on optimizing material and manufacturing costs of components and improving their efficiency and operational durability to develop sustainable and economical solutions.

 

Production of Green Hydrogen through Electrolysis

An efficient and cost-effective hydrogen production is the basis for a competitive hydrogen economy. Fraunhofer IFAM is researching innovative electrolysis processes to improve efficiency, lifespan, and economic viability of the systems:

Alkaline Electrolysis (AEL):

Proven technology with a high level of maturity, which we continue to optimize in terms of efficiency, material usage, and lifespan

PEM and AEM Electrolysis:

Particularly suitable for dynamic operation with fluctuating wind and solar energy, ideal for direct coupling to renewable energies

Seawater Electrolysis:

Innovative approaches where catalysts, membranes, and materials are developed that work reliably even under highly corrosive conditions

Our institute has an extensive laboratory infrastructure, including laboratory electrolyzers, analytical methods, and test benches, which allow us to investigate new materials under realistic conditions.

 

Transport and Storage of Hydrogen: Efficient Solutions for Industry and Mobility

The availability of safe and economical transport and storage systems is crucial for a comprehensive hydrogen supply. Our research includes, among other things, the following areas:

Pressure and cryogenic storage:

Tank and transport systems must withstand high pressures (between 300 and 700 bar, e.g., in vehicle construction) or cryogenic temperatures (down to -253 °C, e.g., in aerospace). Our researchers are working on fiber-reinforced composites for lightweight, safe pressure tanks, optimizing sealing systems to minimize hydrogen losses, and analyzing the long-term behavior of materials to prevent material embrittlement. They also test materials that function reliably even at cryogenic temperatures

LOHC (Liquid Organic Hydrogen Carrier):

Liquid organic hydrogen storage systems chemically bind hydrogen and enable safe, loss-free storage at ambient pressure and temperature. We develop reaction-resistant tank coatings and optimize catalysts for hydrogen release

Metal Hydrides:

Metal hydride storage offers a particularly high volumetric storage density and is ideal for applications with limited space. At the institute, we develop composite materials to improve reaction kinetics and increase economic efficiency

POWERPASTE:

POWERPASTE is an innovative, pasty hydrogen storage solution based on magnesium hydride (MgH₂) developed at Fraunhofer IFAM. This technology is ideal when there is no suitable hydrogen logistics or refueling infrastructure available. POWERPASTE is provided in handy cartridges and releases hydrogen as needed in a hydrolysis reactor through paste dosing and water addition.

Condition Monitoring and Corrosion Protection:

For comprehensive supply, a hydrogen network with pipelines and large storage facilities is necessary. Our R&D services in this area range from sustainable fouling and corrosion protection for offshore hydrogen pipelines to automated condition monitoring of hydrogen storage systems (lead project TransHyDE). Additionally, test methods for realistically representing structural stresses are being developed, and analytical and numerical models are used for verification.

 

Efficient Use of Hydrogen through Fuel Cells

Fuel cells are a central component of many applications—from the automotive and aviation industries to stationary energy supplies and mobile devices. Efficient use of hydrogen requires powerful and economical fuel cell systems. Fraunhofer IFAM develops material and process solutions that make the production of fuel cells significantly more efficient. A focus is on fast, process-secure adhesive bonding processes that can enable so-called 10-Hz manufacturing processes. This allows components to be joined precisely, without distortion, and without the thermal stresses associated with welding processes. Corrosion processes during operation can also be reduced or avoided.

 

Shaping the Hydrogen Economy Together

Would you like to learn more about our research activities, projects, or services in the field of green hydrogen, electrolysis, transport and storage solutions, or fuel cell manufacturing? Please feel free to contact us and join us in shaping the future of a climate-neutral hydrogen economy together with us.