Projects

Division Materials for High-Temperature Technologies

Zirconia-based thermal barrier coatings for extended temperature ranges

PERIOD

PARTNERS

SPONSORS

CONTACT

11/2020 - 10/2023

TU Darmstadt, Dechema

-

Dr. D.E. Mack

Prof. Dr. Robert Vaßen

Links / Informations

Extension of the temperature application range of zirconia-based thermal barrier coatings by alternative coating processes and modified chemical composition; funded by DFG & FVV

Investigation of the layer formation mechanisms and system properties of thermal insulation layer systems on interior surfaces.

Period

Partners

Sponsors

Contact

04/2021 - 03/2023

TU Dortmund, LWT

DFG

PD Dr. Georg Mauer

Links / Informations

-

MAXCOM - MAX phase composites: new materials for elevated temperature service

Period

Partners

Sponsors

Contact

08/2016 - 07/2021

IEK-1

BMBF

Prof. Dr. Jesus Gonzalez-Julian

Links / Informations

This work has been funded by the Germany’s Federal Ministry of Education and Research (“Bundesministerium für Bildung und Forschung”) under the MAXCOM project (03SF0534)

MakTurb - Development of abradable layers

Period

Partners

Sponsors

Contact

11/2020 - 10/2022

Rolls-Royce, Oerlikon Metco

BMWI

Dr. Hanna Heyl

Prof. Dr. Robert Vaßen

Links / Informations

The aim is to develop a new generation of abradable coatings for the high-pressure turbine of aircraft engines

Kelvin - Cold gas spraying and endoscopic solutions for aerospace engine maintenance procedures

Period

Partners

Sponsors

Contact

03/2019 - 05/2022

Rolls-Royce, Lufthansa Technik

BMWI

Dr. Jochen Fiebig

Prof. Robert Vaßen

Links / Informations

In this project, repair processes for high-strength metallic components are developed via cold gas spraying

ParZiVal - Improved thermal barrier coatings

Period

Partners

Sponsors

Contact

04/2021 - 03/2024

Rolls-Royce

BMWI

Prof. Robert Vaßen

Links / Informations

In this project, additively manufactured components are provided with a thermal insulation layer using novel coating processes

DOEFS - Experiment-based service life and sensitivity analysis of degradation mechanisms on rub-on linings

Period

Partners

Sponsors

Contact

04/2019 - 03/2022

Rolls-Royce

BMWi

Prof. Robert Vaßen

Links / Informations

Optimization of abradable layers for the compressor section of aero gas turbines

SFB/TR 103 - Coatings for single crystal alloys

Period

Partners

Sponsors

Contact

01/2019 - 12/2023

Ruhr Universität Bochum, FAU Erlangen-Nürnberg, Rolls-Royce, Siemens, Lufthansa Technik

DFG

Jana Joeris

Prof. Robert Vaßen

Links / Informations

Thermal barrier coatings and repair processes are developed for single crystal materials

LaBeGa - Innovative load-flexible coating systems for gas turbines
Subproject: Development of thermally sprayed thermal barrier coating systems with improved cycling resistance.

Period

Partners

Sponsors

Contact

09/2020 - 08/2023

Oerlikon Metco, MinesParisTech, Safran

BMWI

Jens Igel

Prof. Robert Vaßen

Links / Informations

Development of thermally sprayed thermal barrier coating systems with improved resistance to rapid load changes

Evaluation of local residual stress distributions during local component repair by cold gas spraying

Period

Partners

Sponsors

Contact

04/2021 - 03/2024

KIT

DFG

Prof. Robert Vaßen

Links / Informations

Improvement of repair processes based on cold gas spraying

Division Gas Separation Membranes

PROMETHEUS - Proton and oxygen co-ionic conductors for CO2/H2O co-electrolysis and intermittent RES conversion to methanol and other chemicals towards EU sustainability

Period

Partners

Sponsors

Contact

03/2018 - 06/2021

Aristoteles University Tessaloniki, Helenic Petroleum RES, WZR Ceramic Solutions

BMBF

Prof. Dr. Wilhelm A. Meulenberg

Links / Informations

The project will develop an electrochemical membrane reactor that performs H2O/CO2 co-electrolysis at medium or high temperature with co-ionic (H+ and O2-) ceramic conductors (ci-EMRs) for efficient conversion/storage of renewable energy into synthetic fuels. The main focus is on the temperature range of 400-500°C, where the anionic electrolysis of H2O to H+ and the conversion of CO2 on the other side of the membrane, produces chemicals/energy carriers such as methanol, methane, or at higher temperatures, synthesis gas. The functional layer is a 10-40 µm thick, ceramic proton-conducting membrane that transports H+ through the grid at higher temperatures. On the German side, the focus will be on the development of the membrane structures, as well as the development of improved proton-conducting ceramic materials and suitable starting powders. The main focus will be on the production of the ceramic membrane structure using 3D printing. This technology is by no means state of the art for the necessary, highly complex ceramics, but it promises enormous potential in terms of cost-effective adjustment of an optimal microstructure. For comparison purposes, structures will be produced by sequential film casting. The Greek side will work on process engineering and application-oriented electrochemical characterisation in the project. This project addresses the problem of energy storage with a growing share of renewable energies in the German energy system (Energiewende). The aim is to develop alternative and efficient processes for the production of synthetic fuels. If successful, the processes will also be highly innovative for the production of important basic chemicals. The project topic involves some risks and is therefore not yet being pursued to any great extent by industry.

Forschungszentrum Jülich - Press releases - 3D Printing to Make Synthetic Fuels More Efficient and Cheaper (fz-juelich.de)

AMAZING - Additive Manufacturing for Zero-emission Innovative Green Chemistry

Period

Partners

Sponsors

Contact

12/2020 - 11/2024

Projekt AMAZING: WZR ceramic solutions, hte GmBH, University of Twente, TU Eindhoven, Shell, DoW Chemicals

BMWi

Prof. Dr. Wilhelm A. Meulenberg

Links / Informations

In order to sustainably meet the world's ever-increasing demand for energy and material goods, the use of renewable resources is needed in the fuel and chemical industries. This will be essential to maintain the prominent position of the European chemical industry and to achieve the ambitious EU 2030 targets on climate change, process efficiency and safety. 46 and 36% of energy consumption in Germany and the Netherlands, respectively, is attributable to industry. Improving industrial energy efficiency is therefore an important task for research. The "Amazing" project directly addresses several funding priorities of the Federal Ministry for Economic Affairs and Energy. The focus is on the sector-specific energy optimisation of existing industrial processes as well as the efficient use of secondary forms of energy and the replacement of fossil fuels with renewable energy sources. However, the direct use of renewable electricity in the chemical industry (power to chemicals) is not easy, as the majority of the heat needed to carry out chemical reactions is generated by burning fossil fuels. Replacing large-scale high-temperature cracking processes with electrically driven thermocatalytic activation of alkanes to produce chemical building blocks (e.g. alkenes) is a promising way to reduce COemissions. An alternative to the energy-intensive standard process is to combine mixed ionic-electronic conducting (MIEC) membranes with metal-supported catalysts. In the Amazing project, we aim to develop additive manufacturing technologies such as 3D printing to develop self-supporting catalytic membrane reactor systems that exploit the full potential of RDH membrane reactors. The additive manufacturing routes used promise easy upscaling to full commercial systems.

3D-OTM - Additive manufacturing of oxygen transport membranes

Period

Partners

Sponsors

Contact

07/2019 - 06/2021

WZR Ceramics Solutions

AiF

Dr. Stefan Baumann

Links / Informations

The aim is to use additive manufacturing to produce a membrane component that ensures optimised gas flow and has few, well-defined joints. The connection of supply lines to the component is also realised. The developed product is quantitatively evaluated on the basis of its performance with regard to the separation of pure oxygen from the air. Subsequently, the product is available for academic and/or industrial research on membrane reactors.

The role of interfaces in multiphase ceria-based membranes for use in membrane reactors.

Period

Partners

Sponsors

Contact

01/2018 - 06/2022

WWU Münster, RWTH Aachen

DFG

Dr. Stefan Baumann

Links / Informations

The aim of this project is to identify the cause of the significant permeation rate at low electron conductor fractions in CGO-based composite membranes with spinels as electron conducting phase and to use the comprehensive understanding of the physical properties thus gained so that the ambipolar conductivity (and thus the permeability) of this material system can be maximised. We assume grain boundary phases or positively acting space charge zones at phase boundaries as the cause. The success of the material development will be tested in a membrane reactor on tablets as well as on thin, supported membrane layers with catalytically active surface layers as a function of temperature and pO2 gradient (driving force).

Division Solid Oxide Cells

SynSOFC 2

Period

Partners

Sponsors

Contact

03/2020 - 02/2023

TU München

DFG

Dr. Christian Lenser

Links / Informations

The coupling of a biomass gasifier with a solid oxide fuel cell (SOFC) to produce electricity from biomass is being studied within the framework of a joint project of Forschungszentrum Jülich and TU München, funded by the Deutsche Forschungsgemeinschaft (DFG). The objective of this dissertation is the development of new material combination for the fuel electrode with an improved tolerance against contaminants in the fuel gas. The material systems under investigation include cermets based on Nickel and Gadolinium-doped ceria (GDC) as well as innovative ceramic materials that exsolve nano-scaled catalyst particles during operation. The materials and components developed at IEK-1 will be tested at TU München using synthetic Syngas with controlled amounts of contaminants, in order to investigate the interaction of each molecule with the material.

Solar Hydrogen

Period

Partners

Sponsors

Contact

01/2021 - 12/2023

IEK-2, -5, -9, -11, -14, ZEA-1, DLR, KIT, HZB, HZDR, IPP

HGF

Dr. Mariya Ivanova

Links / Informations

As part of an internal Helmholtz funding (HGF), a proton-conducting electrolysis cell is to be developed to obtain hydrogen that is highly pure and water-free. The energy required for the cell will origin from solar sources.

WirLebenSOFC - Life-time prediction of SOCs

Period

Partners

Sponsors

Funding reference

Contact

03/2021 - 03/20247

Bosch, RJL, KIT, HS Karlsruhe, HS Aalen

BMBF

FKZ 03SF0622B

Prof. Dr. Norbert H. Menzler

Martin Juckel

Links / Informations

Funded by the BMBF as part of the Hydrogen Republic of Germany initiative, the project is working on the specific degradation phenomena of a so-called metal-supported solid oxide fuel cell (MSC) for the reconversion of hydrogen generated via renewable sources. Under the leadership of Bosch and together with the company RJL and the research partners KIT, HS Aalen and HS Karlsruhe, the institutes IEK-1, -2 and -14 are specifically working on the thermal-atmospheric degradation phenomena (material-specific, microstructure-dependent and thermodynamic/kinetic) and the further development of the MSC

https://www.wasserstoff-leitprojekte.de/grundlagenforschung/brennstoffzellen

SOC Degradation 2 - Degradation of SOCs

Period

Partners

Sponsors

Funding reference

Contact

03/2021 - 02/2024

IEK-2, -9, -13, -14, IKTS, DLR, KIT, Bosch, Hexis/mPower, Kerafol, Sunfire, Mann+Hummel, Horiba FuelCon, SOLIDpower

BMBF

FKZ 03SF0621A

Prof. Dr. Norbert H. Menzler

Michael Wolff

Links / Informations

Also based on the Hydrogen Republic of Germany initiative, the BMBF-funded project focuses on specific degradation effects that only occur under electrolysis mode. At IEK-1, alternative fuel gas electrodes are being developed for this purpose and marketable manufacturing processes are being advanced. Broad participation of other German industrial partners (Kerafol, Hexis/mPower, Sunfire, Mann+Hummel, Bosch, Horiba FuelCon, SOLIDpower) as well as external research institutions (IKTS, DLR, KIT) and Jülich institutes (IEK-2, -9, -13, -14) ensures a broad approach to understanding and solving the effects that occur.

https://www.wasserstoff-leitprojekte.de/grundlagenforschung/brennstoffzellen

ReNaRe - Recycling - sustainable use of ressources

Period

Partners

Sponsors

Funding reference

Contact

04/2021- 03/2025

FZJ (IEK-1, -2, ZEA-1), TU BA Freiberg, RWTH Aachen, KIT, FhG-IPA, HZDR, Nickelhütte Aue, Heraeus, Öko-Institut, Dechema, Hexis/mPower, TU München

BMBF

FKZ 03HY111J

Prof. Dr. Olivier Guillon

Prof. Dr. Norbert H. Menzler

Links / Informations

The joint project ReNaRe is part of the technology platform H2Giga. The project is investigating the possibilities of recycling of solid oxide electrolyzer stacks. The focus is on either reuse, remanufacturing or recycling of components. Depending on the stack concept and/or recycling concept, materials or components can be reused directly or have to be reprocessed in a complex way. The focus of IEK-1 is the reuse of the ceramic components of the cell either again in SOCs or in alternative applications.

https://www.wasserstoff-leitprojekte.de/leitprojekte/h2giga

ElChFest

Period

Partners

Sponsors

Funding reference

Contact

01/2022- 12/2024

IEK-2, IAM-ET (KIT), IDM (HSKA)

BMBF

03SF0641A

Dr. Christian Lenser

Links / Informations

In the joint project ElChFest, we work together with our partners in Karlsruhe to develop a solid oxide electrolysis cell (SOEC) based on doped ceria, and optimize the cell as well as the operational parameters. Material-, microstructural and electrochemical investigations will be combined in order to establish a model that allows the calculation of mechanical stresses as a function of the operation point.

Division Electrochemical Storage

EVABATT, Evaluierung fortschrittlicher Festkörperbatteriekonzepte mit hoher Sicherheit und Leistung, (JLU Gießen, Fraunhofer ICT, TU München, IEK-1 & National Cheng Kong University, Feng Chia University, National Universty of Tainan, Industrial Technology Research Institute of Taiwan, National Applied Research Laboratories) November 2017 – Oktober 2020

GrEEn, Grüne Elektrochemische Energiespeicher (RWTH Aachen, WWU Münster, IEK-1, IEK-9), September 2017 – August 2020

INDICATE, In-situ Analysis of Li-Distribution in Cathodes, (WWU Münster, IEK-1), September 2017 – August 2019

LISZUBA, Lithium-Schwefel-Feststoffbatterien als Zukunftsbatterie (JLU Gießen, TU Braunschweig, TU Berlin, IEK-1), Juli 2017 – Juni 2020

BCT, Battery Cell Technology (ContiTech Elastomer-Beschichtungen GmbH, Henkel Electronic Materials N.V., Saueressig GmbH + Co. KG, Adphos Group, FhG-IPA, Uni Stuttgart, IEK-1, WWU Münster, TU Braunschweig), Juli 2017 – Juni 2019

MEET Hi-EnD II, Materials and Components to Meet High Energy Density Batteries (RWTH Aachen, WWU Münster, IEK-1, IEK-2, IEK-9 und IEK-12), Oktober 2016 -September 2019

FELIZIA, Festelektrolyte als Enabler für Lithium-Zellen in Automobilen Anwendungen (BMW AG, BASF SE, IEK-1, IEK-12, TU München, Justus Liebig-Universität Gießen, KIT, Schott AG, VW AG), Januar 2016 – Dezember 2018

BenchBatt, Benchmarking und Validierung der Leistungsfähigkeit und Kosten von Hochenergie- und Hochvolt-Lithium-Ionen Batterien im Vergleich zu Post-Lithium-Ionen Technologien (WWU Münster, IEK-1, IEK-12, TU Braunschweig, Justus Liebig Universität Gießen), Januar 2016 – Dezember 2018

DESIREE, Defect spinels as high-energy and high-performance materials for electrochemical energy storage (IEK-1, IEK-9, RWTH, KIT), September 2014–August 2018

NextGenBatt, Research infrastructure for future battery generations (RWTH Aachen (PEM, IME), Fraunhofer ILT, IEK-1, IEK-9 und IEK-12), The parallel research of evolutionary (development of Li-Ion batteries) and revolutionary concepts ("post-Li-Ion" solid state batteries) along the value chain is the central point that will be realized with the planned investments. Funded by the Federal State of NRW (EFRE-NRW), September 2018 – December 2020

ProFeLi, Produktionstechnik für Festkörperbatterien mit Lithium-Metall-Anode (TU München, IEK-1, IEK-2, Brückner Maschinenbau GmbH & Co. KG, GS GLOVEBOX Systemtechnik GmbH, J. Schmalz GmbH, Zwick GmbH & Co. KG, Volkswagen AG), Februar 2019 – Juli 2022

Naseber, Natriumbasierte feste Sulfid- und Oxid-Elektrolyt Batterien (Volkswagen AG, JLU Gießen, IEK-1, Humboldt-Universität Berlin), Januar 2019 – Juni 2022

HeNa, Herstellungswege für Natrium-Festkörperbatterien (IKTS Dresden, ILT Aachen, IEK-1, IFW Dresden, TU Darmstadt), August 2021 – Juli 2024

Last Modified: 14.11.2022