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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - MAMA-MEA (Mass Manufacture of MEAs Using High Speed Deposition Processes)

Teaser

Summary

The MAMA-MEA project addresses the critical Catalyst Coated membrane (CCM) fuel cell process bottlenecks via the development of the Additive Layer Manufacturing (ALM) concept. The project industrial partners include a CCM manufacturer and an Original Equipment Manufacturer (OEM) as well as two process line developers to ensure the project exploitation is maximised. Three academic institutes and Universities finally provide the scientific and characterisation support for the activities.
As such, the project is not only well-placed to develop a step-change in fuel cell manufacturing capability but will also greatly enhance European competitiveness on the world stage, in this rapidly growing market.

The specific aim of MAMA-MEA is to assess the full complement of coating and printing techniques from a range of industry compatible with ALM before down selecting the most promising technique for full concept development including the reduction of critical raw materials mainly by reducing the scrap and improving the materials utilisation.

The stated objectives are:

â€¢ Identify, evaluate and down select a minimum of two mature deposition methodologies from other industries, for detailed process development, based on CCM component layer specifications and requirements.

â€¢ Develop an integrated additive layer deposited CCM capable of equivalent or superior fuel cell performance to CCMs produced by the current state of the art process, meeting at least a power density 0.67 W/cm2 and a degradation rate of <0.25 %/1000 h.

â€¢ Develop a comprehensive engineering design of a CCM manufacturing line incorporating the new deposition processes, with line speeds in excess of the Topic target of over 50 MW/year.

â€¢ Validate the manufacturing capability of the new process by demonstrating state-of-the-art performance of CCMs in two PEMFC stack tests.

Work performed

â€¢ WP1: WP1 resulted in the selection and final down selection, using a grading matrix, of the techniques deemed the most promising to perform ALM of CCM layers. Several parameters were included in the whole evaluation, encompassing three main areas: ability to meet the specified layer requirements, ability of suitable inks to perform layer deposition by the respective technique, ALM feasibility and associated costs. The whole process was applied to high volume production and five techniques identified for MEA layers and two techniques for the seal layers. Finally, the down selection was carried out to meet MAMA-MEA project mission: introducing a disruptive manufacturing approach to CCM mass production.

â€¢ WP2: Initial ink and proof of printability goals were achieved at M18 using the WP1 down selected methods. Work on the suitability of each techniques for specific ALM layers is still underway and will carry on supporting the work in WP3 during the second period of the project.

â€¢ WP3: The principle of ALM CCM has been proven as samples made on the roll-to-roll pilot line have shown equivalence to standard samples. Importantly, the power target of 0.67 W/cm2 has been met under a range of testing conditions. The quality of the CCMs produced needs to be improved but the fundamental cause of the issues is understood, and mitigation strategies are in place for future pilot trials. This includes utilising some of the other deposition techniques identified in WP2. Several potential QC methods have also been identified and are being evaluated with regards to their suitability for application in the quality control stations on the production line for MAMA-MEA.

â€¢ WP4: this work package is only starting at M18 and will include the design od an ALM high volume process line as its final output.

â€¢ WP5: At M18 this work package has defined the testing protocols to be used by all partners and has carried out the baseline test for ALM CCM samples to be compared against.

â€¢ WP6: Project management has proceeded smoothly, with effective communication between the partners. All 15 deliverables that were due to be submitted by M18 have been submitted, and two project milestones due by M18 have been met. Project progress was backed up by strong communication between the partners with intra-WP calls and meetings, plus monthly project web-meetings and also face-to-face project progress reviews with the Technical Committee at 6-monthly intervals.

â€¢ WP7: Dissemination and communication activities have ranged from outreach activities, web presence, newsletters and flyers at various events. 15 scientific presentations and posters have already taken place by M18.

Final results

The MAMA-project, having reached its mid-point, has achieved its technical targets for the reporting period. A range of coating and printing techniques were assessed and down selected enabling initial concepts to be fabricated on a roll-to-roll pilot line already demonstrating the expected target and durability performance. Further benefit is expected from other alternative down selected techniques which will be pursued further during the second period of the project.

These breakthrough achievements coupled with the strong EU supply chain being developed and the direct â€œat scaleâ€ commercial viability of the components will draw a clear path forward for fuel cells to become reality.

MAMA-MEA is a project driven from a clear manufacturing need with the stated aim of taking ALM from MRL3 to MRL6. As such, all work packages are presenting exploitation opportunities for the industrial partners. The direct involvement of leading EU process suppliers is also bringing a shared technical understanding which will also reinforce these ties and exploitation opportunities going forward.