Industry and research institutions in Germany are working together on the HyCoFC project to develop durable and cost-effective fuel cell components aimed at enhancing performance in heavy-duty transport. The initiative, which includes Thyssenkrupp Steel and the Fraunhofer Institutes ILT and UMSICHT, seeks to provide emission-free alternatives for freight transport.
The project aims to create a fuel cell stack that is lighter than battery-electric systems, potentially increasing payload capacity for trucks. Unlike battery-electric vehicles, fuel cell trucks could also benefit from significantly shorter refueling times.
HyCoFC is receiving approximately €3 million in funding under the Energie.IN.NRW innovation competition. The collaboration includes project coordinator Thyssenkrupp Steel alongside industry partners FEV, Schepers, and Cleanlaser.
Fuel cells for heavy transport must withstand demanding conditions such as temperature fluctuations, mechanical stress, and corrosive environments. To address these challenges, the HyCoFC project is developing hybrid compound bipolar plates that integrate a metallic carrier film with a conductive compound layer. These components offer enhanced electrical conductivity, mechanical stability, and corrosion resistance, with the goal of extending fuel cell service life to around 30,000 hours while reducing production costs.
“This versatility makes the technology an ideal component for the energy transition in the mobility sector,” said Friederike Brackmann from the Fraunhofer Institute for Laser Technology ILT.
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Thyssenkrupp Steel is responsible for manufacturing the metallic carrier film, which includes a chrome layer to improve corrosion resistance. Meanwhile, Fraunhofer UMSICHT is optimizing the compound layer’s electrical and thermal conductivity by refining material selection and composition. Fraunhofer ILT is advancing laser-based production technologies to enhance the functionality of these hybrid bipolar plates.
Research is being conducted at the Fraunhofer ILT’s Hydrogen Lab, which features specialized infrastructure for hydrogen technology development. The lab includes modern laser processing systems and test benches spread over 300 square meters, allowing for real-world evaluation of production methods.
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ILT researcher Friederike Brackmann is investigating laser welding techniques to ensure the bipolar plates are hydrogen-tight and reproducible. Tobias Erdmann, another ILT scientist, is working on optimizing the contact resistance between the plates and the gas transport layer.
“We expose the conductive graphite filler material in the contact area with the gas transport layer,” Erdmann explained. “Unlike mechanical grinding processes, ultrashort pulsed laser radiation can selectively remove the plastic without damaging the filler material.”
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According to Fraunhofer ILT, the hybrid compound bipolar plates have the potential to improve the longevity and applications of fuel cells across multiple sectors, including heavy transport, maritime industries, and stationary energy systems.
“A particular focus at HyCoFC is on developing processes that enable economically scalable and cost-efficient production in large quantities,” Erdmann said. “We are focusing on the roll-to-roll process, which ensures continuous and high-quality processing of the materials. We want to implement and test this next.”