Blick in die Kältekammer eines Teststands für Brennstoffzellen Brennstoffzellen

DegradMap – Spatially Resolved, Segmented Analysis of Fuel Cell Degradation During Cold Starts

Optimisation of Cold-Start Performance and Service Life of Fuel Cells Using Segmented Measurement Methods

As part of the IGF project DegradMap, the ZBT is developing new measurement methods and operating strategies to reduce frost damage in fuel cells and enable safe, rapid cold starts even at temperatures as low as −30 °C.

Problem: Cold Start and Degradation of Fuel Cells

At low temperatures, residual and product water in PEM fuel cells can freeze, preventing startup or causing irreversible damage to cell components. At the same time, significant temperature and voltage differences arise within the fuel cell stack during cold startup, which can accelerate degradation.

Investigating these processes has so far been time-consuming and costly. Standardised test procedures are lacking, and conventional measurement methods provide only limited information about local stresses and damage mechanisms. This hinders the development of reliable and durable fuel cell systems for operation in freezing conditions.

Methodology and Application: Segmented Measurements for Optimised Operating Strategies

The ZBT combines experimental cold-start and cycle tests with spatially resolved in-situ diagnostics and subsequent ex-situ material analyses. In this process, local temperature, current, and voltage distributions are correlated with damage patterns such as cracks or delaminations in the stack components.

Based on these investigations, optimised cell and stack designs, more efficient purging and cold-start procedures, and test protocols for evaluating cold-start robustness are being developed. The results are intended to shorten development and testing times, increase the service life of fuel cells, and establish a data foundation for the standardisation of cold-start tests.

Project information

  • Project Acronym: DegradMap

  • Project Title: Spatially Resolved, Segmented Analysis of Fuel Cell Degradation During Cold Starts

  • Project Duration: 01. October 2026 – 31. March 2029

  • Funding: Joint Industrial Research (IGF)

  • ZBT Project Budget: €255,411.24

  • Project partner: ZBT – Zentrum für BrennstoffzelenTechnik GmbH

  • Grant Reference Number: IGF 01IF25523N

Contact

Verena Lukassek
Verena Lukassek, Staff photo

Skills

The project builds on the ZBT’s extensive expertise in the fields of electrolysis, measurement and testing technology, aging studies, as well as modeling and data-driven analysis. The existing test infrastructure and expertise enable the experimental investigation and evaluation of electrolysers under dynamic operating conditions and are also available to industry partners as part of development services and contract research.

  • Measurement and Testing Services – Experimental investigation and characterisation of electrolyzers and hydrogen systems under realistic operating conditions.
  • Modeling and Simulation – Modeling, data-driven analysis, and simulation for the evaluation and optimization of hydrogen and electrolysis systems.
  • Development Services – Development, testing, and optimization of components and systems for hydrogen and electrolysis technology.

 

learn more about our services

Other current projects

Blick in die Kältekammer eines Teststands für Brennstoffzellen Brennstoffzellen

DegradMap – Spatially Resolved, Segmented Analysis of Fuel Cell Degradation During Cold Starts

As part of the IGF project DegradMap, the ZBT is developing new measurement methods and operating strategies to reduce frost damage in fuel cells and enable safe, rapid cold starts even at temperatures as low as −30 °C.

Read more

ELYSeal – Service life and safety of seals in PEM electrolysers

ZBT and Fraunhofer IMWS are developing improved testing and evaluation methods for seal materials in safe and durable PEM electrolysers.

Read more

RADAR-PEM – ESR-Based Short-Term Diagnostics for the Aging of PEM Electrolysis Membranes

As part of the IGF project RADAR-PEM, the ZBT and the MPI-CEC are developing an ESR-based short-term diagnostic method for the direct measurement of membrane aging in PEM water electrolysis.

Read more

pAST-EL – Predictive AST Protocols for Alkaline Electrolysis

As part of the pAST-EL project, ZBT and DLR are developing predictive stress tests and machine learning models to detect degradation more quickly, predict service life more reliably, and optimise operating strategies for electrolysers.

Read more
Röntgenmikroskopaufnahmer einer Membran-Elektroden-Einheit (MEA)

grELjet – Graded Catalyst Layers for PEM Electrolyzers

As part of the grELjet project, ZBT is collaborating with Fraunhofer ENAS to develop spatially resolved, optimised catalyst layers designed to reduce the iridium requirements of PEM electrolysers and increase their efficiency.

Read more
Teststand für Ammoniak-Craccker in großem Labor

NH3-HRS – Scalable Ammonia Cracker for Hydrogen Fueling Stations

The NH3-HRS project is developing a compact system that converts ammonia directly into high-purity hydrogen at hydrogen refueling stations.

Read more

H2B – Is Hydrogen the Right Solution for Energy-Intensive SMEs?

New Interreg Project H2B Provides Entrepreneurs with Clarity on Hydrogen as an Energy Solution.

Read more
Two scientists in white lab coats are examining a material sample in the Electrochemical Components Laboratory.

GALWANi – Nanowire Electrodes for Alkaline Water Electrolysis

The GALWANi project is developing customised nickel and nickel-iron nanowire electrodes for more powerful and efficient alkaline electrolysers.

Read more