NH3Avi – Process for the inline production of metal-supported SOFC MEAs for aviation

Climate-neutral flying requires new energy sources – and new production technologies. In the NH3Avi project, we are developing metal-supported SOFC membrane electrode assemblies (MEA) for use with ammonia in aviation.

Ammonia can be used in aviation as a climate-neutral fuel that is converted directly into electricity in solid oxide fuel cells (SOFC). The recently launched NH3Avi project is pursuing three core objectives: a novel metal-supported cell design for a proton-conducting SOFC in ammonia operation, higher cycle stability for aviation requirements and a new, inline-capable manufacturing process for the MEA multilayer system.

The ZBT collaborates with the Fraunhofer Institute for Laser Technology (ILT), Aachen, the Chair of Materials for Electrical Engineering 2 (IWE2), RWTH Aachen University and the Leibniz Institute for Plasma Research and Technology (INP), Greifswald.

What is the content about?

Ammonia is a carbon-free energy source that can basically be used directly in SOFC systems – without additional process steps as an educt.

At the same time, NH3Avi addresses central hurdles of today’s SOFC technologies for aviation: long start-up times and low cycle stability at very high operating temperatures.

The approach therefore relies on proton-conducting electrolytes (operation at approx. 400-600 °C) and a layer system on a metallic, porous carrier in order to accelerate temperature changes and increase robustness.

How is inline production achieved?

A central project principle is the consistent focus on inline-capable process chains: slow furnace processes for electrolyte crystallization are replaced by dynamic laser processes and no vacuum processes are used.

Together, the partners cover complementary process steps – from plasma spraying and morphological analysis (INP) to precursor systems and barrier layers (IWE2) to layer deposition and electrochemical characterization (ZBT) as well as laser sintering/laser functionalization (ILT).

Project information

Development of an inline-capable process for the production of metal-supported SOFC MEAs for use in aviation

Project acronym: NH3Avi

Project title: Development of an inline-capable process for the production of metal-supported SOFC MEAs for use in aviation

Duration: October 1, 2025 – January 31, 2029

Funding code / Project management organization: 20M2439A, DLR

Program context: LuFo Climate VII-1 KTF – “Climate-neutral flying”

Project partners:

Fraunhofer Institute for Laser Technology (ILT), Aachen
Chair of Materials in Electrical Engineering 2 (IWE2), RWTH Aachen University
Leibniz Institute for Plasma Research and Technology e.V. (INP), Greifswald
ZBT – The Hydrogen and Fuel Cell Center

ZBT Labor Ammoniak Cracker Anlage Camp Fire Projekt

Questions gladly answered

Robin von Mallinckrodt

+49 203 7598-2351

r.vonmallinckrodt@zbt.de

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