Measurement and Testing Procedures

Material and system testing for fuel cell and electrolysis technology

ZBT offers a comprehensive portfolio of measurement and testing procedures for components and systems in hydrogen and fuel cell technology. The focus is on analytical procedures for material characterisation, electrochemical testing methods, quality testing during development and investigations into ageing behaviour. The services support research, product development and industrial quality assurance.

Ex-situ material analysis

ZBT offers a wide range of ex-situ analysis methods for characterising materials and components. Modern methods such as X-ray microscopy (XRM), X-ray diffractometry (XRD) and scanning electron microscopy (SEM) enable detailed investigation of structural and chemical properties. The portfolio is supplemented by specific methods for H₂ stability, material screening and non-destructive quality control, such as in the BEPPEL project. These analyses provide the basis for targeted material development and fault analysis in fuel cell and electrolysis systems.

Analytics portfolio: Structures, composition, stability

ZBT offers a wide range of ex-situ material analysis for the characterisation of materials and components along the entire hydrogen value chain.

Typical methods:

  • Structural analysis: X-ray microscopy (XRM), scanning electron microscopy (SEM), µ-CT

  • Phase/element analysis: XRD, EDX, FTIR

  • Thermal & chemical stability: TGA, DSC, H₂ resistance tests

Application examples:

  • Diffusion layer characterisation (porosity, conductivity)

  • Corrosion behaviour of bipolar plates

  • Material screening for new systems (e.g. AEM, PEM)

The aim is to optimise materials specifically for performance, service life and processability.

Quality assurance &
process analysis

Reproducible material properties are crucial for the industrial application of fuel cell technology. ZBT develops quality assurance processes along the entire production chain.

Key aspects:

  • Layer thickness and layer homogeneity analyses

  • Inline-capable testing methods

  • Particle analysis for catalyst coatings

  • Beppel: optoelectronic test method for BPPs

Objective:

  • Stabilise manufacturing processes

  • Reduce scrap

  • Interface for industrial scaling



Qualitätskontrolle von Bipolarplatten mit dem BePPel-Teststand

In-situ component qualification

The ZBT carries out a wide range of electrochemical in-situ processes for the validation of fuel cell components under realistic conditions. These include run-in procedures, current-voltage characteristics, electrochemical impedance spectroscopy (EIS), cyclovoltammetry (CV), high-frequency pulse measurement (H₂P), accelerated ageing tests (AST) and PFAS analysis. In addition, hardware-in-the-loop test benches enable the evaluation of components in a system context. This allows material and process developments to be directly traced back to operating characteristics.

Electrochemical
commissioning &
characterisation

The aim is to precisely determine electrochemical parameters under real operating conditions. Standardised protocols and individually adapted test strategies are used for this purpose.

Typical methods:

  • Run-in procedures for MEAs

  • Polarisation curves (characteristic curves)

  • Electrochemical impedance spectroscopy (EIS)

  • Cyclovoltammetry (CV)

  • H₂ permutation (H₂P)

  • Accelerated stress tests (AST)

Areas of application:

  • MEA validation

  • Component comparison

  • Performance benchmarking

  • Identification of degradation mechanisms



Greenlight Teststand, Julian Kapp

System-related tests &
HIL validation

Component tests are also carried out at ZBT under simulation-supported system conditions – a decisive step towards transfer to real-world applications.

Core approaches:

  • Hardware-in-the-loop (HiL) tests for system components

  • Modular test cells for metallic BPPs

  • PFAS analysis for seals and heat exchangers

  • Comparison of test data with modelling results

Benefits:

  • Evaluation in the system context

  • Parameterisation for operating strategies

  • Preparation for field conditions

Test-Brennstoffzelle

Test procedures

In addition to standardised quality tests, ZBT develops application-specific test methods for components and materials. Examples include quality-assured test series for gas diffusion layers (GDL) and standardised procedures for metallic and graphitic bipolar plates. The test methods are used both in the laboratory and in the production environment and help to ensure consistent product properties throughout the entire manufacturing process.

Component-specific test methods

There are specific test procedures for each component class, which have either been standardised or further developed in parallel with research.

Examples:

  • Gas diffusion layers (GDL):
    QM test reports (e.g. permeability, compressibility)

  • Bipolar plates (BPP):
    Standardised QA methods for geometry, coating, conductivity

  • Seals:
    Tests for media resistance and adhesion

Special Features:

  • Combination of experimental test benches with numerical analysis

  • Feedback with manufacturing and design development



Qualitätskontrolle von Bipolarplatten mit dem BePPel-Teststand

Ageing Analyses

The ZBT investigates the degradation behaviour of individual components such as MEAs, bipolar plates and seals, as well as complete fuel cell stacks and system components. Chemical, structural and electrochemical methods are used for ageing diagnosis. These analyses form the basis for service life predictions, conclusions about damage mechanisms and the optimisation of materials and operating strategies.

Component-based
ageing analyses

Investigation of age-related changes at various levels:

Membrane electrode assemblies (MEA):

  • Chemical & electrochemical degradation

  • Analysis by EIS, CV, material cross-sections

Bipolar plates (BPP):

  • Corrosion, coating degradation

  • Long-term exposure, in-situ characterisation

Seals & subsystems:

  • Media resistance, material fatigue

  • Microscopy & FTIR analyses

Stacks and Systems:

  • Performance Degradation under real loads

  • Use of HIL, Monitoring & Diagnostic Procedures

Contact Person

Services | Measurement and Testing Procedures

Verena Lukassek
+49 203 7598-2343
Verena Lukassek

Contact Person

Services | Compound Technology

Dr. Marco Grundler
+49 203 7598-1175

Further services offered by ZBT

Development

Development work at the ZBT includes the systematic design, material development and operating strategy of electrochemical components. The aim is to optimise fuel cell and electrolysis systems for specific applications along their entire value chain – using established CAD tools, laboratory-based materials research and simulation-based control concepts.

Consulting and studies

Whether you have initial ideas or concrete projects, we provide consulting services along the entire innovation chain: from the selection of suitable technologies, infrastructure planning and safety requirements to life cycle analysis and approval issues. Together, we analyse potential, identify relevant standards and develop scientifically sound decision-making bases.

Modelling & Simulation

Using physically based models and simulation-based approaches, we analyse transport and reaction processes along the hydrogen value chain – from porous materials to cells to entire plants. Our models help to understand systems, identify weak points and efficiently develop new solutions.