HyCoFC research project aims to develop sustainable fuel cells for heavy-duty applications using innovative materials

Heavy freight transport, especially freight traffic, contributes significantly to global CO₂ emissions. In Europe, road freight transport accounts for about 30 per cent of emissions in the mobility sector. So far, fossil fuels have dominated here, as battery-electric solutions carry a huge additional weight due to the batteries required, which affects the potential payload. Moreover, the associated requirements for charging currents and charging times pose significant limitations for use in heavy truck applications. Fuel cells offer a promising alternative, as they combine high energy density with fast refuelling.

Fuel cells for heavy transport need to be particularly robust and durable as they are used under demanding conditions. Temperature fluctuations, mechanical stress and corrosive environments place high demands on the materials and processing of individual components. This is where the HyCoFC project comes in. The combination of a metallic carrier film with a conductive compound film combines the advantages of both materials. The large-format hybrid compound bipolar plates offer good electrical conductivity, mechanical stability and excellent corrosion resistance - properties that are crucial for heavy transport. These plates are designed to improve the service life of fuel cells while reducing production costs.

Moreover, the modular structure of the fuel cell stacks allows scalability for different application areas, from commercial vehicles to ships and even stationary applications. "This versatility makes the technology an ideal component for the energy transition in the mobility sector," explains Friederike Brackmann of the Joining and Separation department at the Fraunhofer Institute for Laser Technology ILT.

The HyCoFC project is funded as part of the "Energie.IN.NRW" innovation competition, which is part of European regional funding. The total duration of the project runs from 15 June 2024 to 14 June 2027. With total funding of around €3 million, the project is supported by a strong financial base that enables the partners from science and industry to carry out extensive research and development work. In addition to Fraunhofer ILT, Fraunhofer UMSICHT is involved on the scientific side. The industrial companies are project coordinator Thyssenkrupp Steel as well as FEV, Schepers and Cleanlaser.

Thyssenkrupp Steel produces chromium-coated metal carrier film to improve corrosion resistance and adhesion properties to the composite film. Fraunhofer UMSICHT specifically controls the electrical and thermal conductivity of the composite film. It does this by selecting specific materials and refining their composition. As part of the project, Fraunhofer ILT focuses on the further development of laser-based technologies for the production and functionalisation of hybrid composite bipolar sheets.

Friederike Brackmann mainly deals with connection challenges. Her colleague Tobias Erdmann from the Surface Technology and Die Removal Department at Fraunhofer ILT is responsible for the selective decoating of the composite elements using laser radiation and the final electrochemical characterisation of the hybrid stack. Using various laser techniques, they apply microstructures to the components to improve the bonding between the metal and polymer-based components. They are also developing processes to remove material layers. This maximises the electrical conductivity of the bipolar plates.

At the Fraunhofer ILT Hydrogen Lab, researchers will find an extensively equipped infrastructure. It is specifically focused on the practical development and optimisation of hydrogen technologies. State-of-the-art laser technology test facilities and test benches are set up in an area of 300 square metres. These allow researchers to test individual production steps as well as complete process chains and specific industrial applications under realistic conditions. They can then further develop their results.

The combination of innovative materials and production methods not only meets the requirements of heavy-duty transport, but also sets new standards in fuel cell technology. The hybrid composite bipolar plates developed offer the potential to significantly extend the service life of fuel cells. Furthermore, they can broaden the range of applications: from heavy-duty vehicles to maritime applications and stationary systems. The project opens up a wide range of prospects for a climate-friendly energy supply.

Close cooperation between the project partners and support from funding programmes are the basis for the successful implementation of the results in practice. "A particular focus of the HyCoFC research project is the development of processes that enable economically scalable and cost-efficient high-volume production," says Tobias Erdmann. "We are focusing on the roll-to-roll process, which guarantees continuous and high-quality processing of the materials. This is what we want to implement and test now."

Source: Fraunhofer ILT – Featured image: Fraunhofer UMSICHT ( In the HyCoFC research project, researchers are working on sustainable, cost-effective and powerful fuel cells for heavy-duty applications. Innovative material combinations and advanced laser technologies are being utilised.)

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