ZEISS Power & Energy Solutions

Quality Assurance for Electrolyzers

Reliable components through inspection and quality data

Full coverage of electrolyzer applications

Electrolyzers play a crucial role in converting electrical energy into chemical energy by splitting water into hydrogen and oxygen. When powered by renewable energy, this process generates green hydrogen, a sustainable option for long-term energy storage.

The efficiency of hydrogen production relies on the quality of all system components. In addition to the core electrolyzer stack, subsystems like hydrogen compressors, storage tanks, and purification systems must function reliably to prevent failures such as leaks or inadequate cooling. To ensure optimal performance and reliability, detailed inspections of these components are vital. The ZEISS portfolio provides comprehensive inspection solutions to support the integrity of electrolyzer systems.

Electrolyzer systems quality management

The electrolyzer stack is the heart of the electrolysis process, consisting of critical components such as the bipolar plate (BPP) and the membrane electrode assembly (MEA). The quality of each individual cell is vital for the overall performance and efficiency of the system. To meet stringent industry standards, it is essential to inspect all cell components for geometric specifications, as well as the integrity of porous and diffusion layers, and to identify potential surface defects, including contamination.

ZEISS solutions provide support to ensure quality compliance throughout the entire value chain of electrolyzer production, helping manufacturers achieve optimal performance and reliability.

Cell quality inspection

Bipolar plate

There are typically more than one hundred individual cells in a single stack. Efficient generation of hydrogen depends on the guaranteed quality of each individual cell. The bipolar plate provides mechanical stability while ensuring the flow of media and the electrical connection between adjacent cells in the series.
Membrane and electrode inspection

Membrane electrode assembly

The process of splitting water in the MEA is the source of hydrogen production in the stack. Electrodes are positioned on each side of the membrane and contain the relevant catalysts. These electrodes can be applied directly to both sides of the membrane (Catalyst-Coated Membrane) or to the respective gas diffusion layer (Catalyst-Coated Layer).
Stack

The individual cells, including components such as bipolar plate, membrane, catalyst layers and gas diffusion layers, are stacked to built the electrolyzer system. The power output of the system is determined by the number if individual cells. Stacking accuracy and compression of the electrolyzer assembly are crucial to ensure the system operates without leakage, loss of efficiency, or critical deformation of the stack.
Compressor

For media supply and storage, several components are critical to the systems. In addition to water supply and process cooling, hydrogen and oxygen compression are particularly important. This is accomplished using high-volume compressors to facilitate throughput and store hydrogen and oxygen in containers.

ZEISS Hydrogen Solutions at every manufacturing step

Optimal functionality in electrolyzer systems requires attention to several key factors. Ensuring a smooth flow of gas and coolant is essential, along with precise stack alignment. Thorough inspection of bipolar plate coatings is necessary to prevent defects that could compromise efficiency. Consistency in membrane electrode assembly layers, accurate lateral alignment, and regular monitoring of stacked components are critical. Additionally, tight tolerances enhance efficiency, prevent leakage, and ensure seamless operation, with designs tailored for varying compression volumes.

Microstructure formation on bipolar plate

The challenge

To ensure optimal performance, it is crucial to maintain an unhindered flow of gas and coolant through the specially designed microstructures. This requires precise dimensional accuracy of the outer contours, recesses, and geometric elements to guarantee proper stack alignment.

Our solution

Chromatic white light measurement is achieved using ZEISS DotScan sensor mounted on a ZEISS CMM equipped with a rotating probe head. Full surface evaluation is conducted using optical 3D scanning technology provided by ZEISS ATOS Sensors. For detailed imaging, ZEISS Axio Imager 2 light microscope offers in-depth 3D polished micrographic analysis. To ensure optimal preparation for plate joining and stacking, optical contour measurement is conducted using ZEISS O-INSPECT.

The integration of ZEISS CMMs, Optical Solutions, and Microscopy Solutions delivers precise and reliable measurement and evaluation capabilities.

ZEISS CMMs

ZEISS Optical Solutions
Coating of plates, membrane and catalyst layer

The challenge

BPP coating is vital for the efficiency of electrolyzers. Corrosion protection coating must be checked for cracks, bubbles, and defects, and the thin steel layers for surface defects to prevent failures or performance drops.

Avoiding contaminants is essential for optimal performance and longevity. Sample section tests ensure MEA consistency, and checking MEAs for coating defects ensure system reliability.

Our solution

ZEISS VMMs, Microscopy, and X-Ray Solutions offer precise analytical capabilities. Particles are identified with ZEISS Axio Zoom V.16, analyzed via electron microscopy, and processed with ZEISS software, capturing characteristics like size, shape, quantity, composition, origin, and metallic content for particles over 5 μm. Layer continuity and thickness are assessed with ZEISS Axio Imager for precise optical inspection. Non-destructive 3D volume acquisition is achieved with ZEISS Xradia 620 Versa, featuring two-stage magnification.

ZEISS O-INSPECT duo provides automated high-resolution imaging. Nanometer-scale quantification of coated plate roughness and topography is performed with ZEISS LSM 900 widefield confocal microscope.

ZEISS VMMs

ZEISS Microscopy Solutions
Stacking and deformation

The challenge

One of the key challenges for electrolyzer stacks is ensuring the precise lateral alignment of individual plates and overall height. Continuous monitoring of stacked components, including bipolar plates and membrane electrode assemblies, is essential to maintain uniformity in stack layers and their properties. Additionally, maintaining appropriate stack compression and tolerance during operation is vital for optimal functionality and efficiency.

Our solution

For electrolyzer metrology, stacking alignment on both sides is captured using ZEISS DotScan sensor for non-contact measurement or a tactile probe on a ZEISS Coordinate Measuring Machine (CMM). This method ensures precise alignment and enhances the accuracy of electrolyzer stack assembly, leading to improved performance and reliability.

ZEISS CMMs
Dimension and accuracy

The challenge

The challenge involves maintaining tight tolerances to enhance operational efficiency, prevent leakage, and ensure smooth performance. Furthermore, different designs and throughputs must be tailored to accommodate the overall volume that requires compression.

Our solution

High-accuracy Coordinate Measuring Machines (CMMs) are employed to cover all relevant dimensions, complemented by a multi-application sensor system (MASS). This setup ensures precise lateral alignment of individual plates and overall height, which is crucial for proper operation.

ZEISS CMMs for high volume compressors

08.01.2025

Success Story Fraunhofer IWU

The Fraunhofer IWU Chemnitz, Germany, develops processes for the production of bipolar plates. ZEISS metrology is used for absolute accuracy inspection.