Thesis - PEM Electrolyser(EC) development: 3D-FEA Simulation frontloading approach

According to the increasing demand for H2 in the green energy industry, Polymer Electrolyte Membrane Electrolyzer technology is gaining more attention. This thesis explores support for the design development of a PEM electrolyser stack using advanced FEA tools. The focus is on static structural simulations of the MEA under cross pressure to understand the deflection and deformation of PTL and GDL, and to develop design rules for b ipolar p lates (BP) design (channels width, shape,...). A 2/3D FEA simulation workflow needs to be established as a basis for advanced AI/ML (machine learning) technology to support the design of single unit cells of PEM EC, either for design initiation or optimization. Utilizing existing FEA capabilities and features, as well as automation, a parameterized unit cell segment and later a full unit cell model should be established to feed AI methods. Literature Review: Review relevant requirements for the mechanical durability of PEM EC Design and load case selection: Selection of relevant load cases and definition of initial design features for design optimization Workflow: Development of suitable meshing and simulation (FEA) workflow for segment and full unit cell FE model with focus on BP design in relation to PTL and GDL behavior Data Analysis: Evaluate deflection, deformation of PTL/GDL and contact conditions at interface with BP for selected designs under selected loading conditions Develop initial design rules and define AI/ML setup: Compile parameter sets to feed AI optimization tools and develop initial design rules/curves for acceptable plate channel widths, shape, etc. Documentation and Presentation: Document the work and present findings to team members